Neste trabalho estudou-se a viabilidade e sensibilidade do monitoramento em linha, utilizando a espectroscopia NIR, da evolução das concentrações dos monômeros e do polímero, e do tamanho médio das partículas, em processo de copolimerização de acetato de vinila e acrilato de butila em emulsão ao longo das seções de um reator contínuo pulsado de pratos perfurados. Para a elaboração de modelos de calibração NIR destas variáveis foram realizadas reações em um reator tanque agitado de mistura, correlacionando os dados experimentais adquiridos via gravimetria e cromatografia gasosa para a determinação da concentração dos monômeros residuais e a espectroscopia de correlação de fótons para a determinação do tamanho médio das partículas, com os espectros coletados simultaneamente utilizando uma sonda de imersão no modo de transflectância. O modelo de predição NIR foi calibrado utilizando o pacote computacional OPUS próprio do equipamento NIR (FT-NIR IFS 28N) através da ferramenta QUANT baseada em métodos multivariados PLS e PCA. O uso da segunda derivada com 25 pontos de alisamento e da primeira derivada com 17 pontos de alisamento foram escolhidas como melhores pré-tratamentos para as concentrações dos monômeros e o tamanho médio das partículas, respectivamente. A validação dos modelos foi realizada com reações conduzidas no reator continuo pulsado de pratos perfurados inserindo a sonda NIR nas diferentes seções da coluna. Os resultados apresentaram uma concordância satisfatória entre os dados experimentais medidos off line e os resultados preditos pelos modelos de calibração. As predições feitas a partir dos modelos de calibração NIR serviram para a estimativa de outros variáveis importantes no processo de copolimerização, tais como, a conversão global e individual, composição do copolímero e numero de partículas. Estas variáveis estimadas foram também comparadas satisfatoriamente com os valores correspondentes obtidos a partir de dados medidos experimentalmente. Adicionalmente, o monitoramento foi capaz de detectar a ocorrência de alguns distúrbios operacionais, tais como, paradas de alimentação dos reagentes, verificando-se sua sensibilidade de detecção de problemas em tempo real, os resultados reportaram com sucesso os desvios produzidos pela perturbação operacional. Os resultados mostraram que é possível realizar com sucesso o monitoramento em linha, in situ e em tempo real, de diferentes variáveis simultaneamente, no processo de copolimerização em emulsão em um reator continuo com potencial alternativa para uso em ambiente industrial. / This work deals with the study of the viability and sensitivity of the on-line monitoring, using NIR spectroscopy, of monomers and polymer concentration and average particle size during continuous vinyl acetatebutyl acrylate emulsion copolymerization carried out in a novel tubular pulsed sieve plate reactor. For the elaboration of NIR calibration models of these variables, reactions were performed in a stirred tank reactor, and the experimental data of residual monomers concentrations obtained by gravimetry and gas chromatography, and average particle size obtained by photon correlation spectroscopy were correlated with the spectra collected simultaneously in the process using an immersion probe in transflectance mode. The NIR calibration model was obtained by using the built-in computational package OPUS-QUANT in the NIR equipment (FT-NIR IFS 28N) based on PLS and PCA multivariate methods. The use of second derivative with 25- point-smoothing filter and the first derivative with 17-point smoothing filter were chosen as the best pre-treatments for the monomers concentration and the average particle size, respectively. The model validation was tested with reactions carried out in a continuous pulsed sieve plate tubular reactor, in which a NIR probe was inserted into different sections along the column. The results showed a reasonable agreement between experimental data and NIR predicted data. These results were also used to estimate other important variables in the copolymerization, such as the global and individual conversion, the copolymer composition and the number of particles. These estimated variables were also satisfactorily compared with corresponding data estimated from the experimental data. In addition, the NIR monitoring was able to detect some operational disturbances, such as the interruption of reagent feeding, thus showing its sensitivity for successfully detecting process disturbances in real time. The results indicate that NIR spectroscopy is a powerful tool for in-line, in-situ, real-time monitoring of different variables simultaneously during emulsion copolymerization process carried out in a novel continuous reactor, being a potential alternative for use in a real industrial environment.

A técnica de polimerização em emulsão tem sido usada cada vez mais na indústria de tintas, resinas, plásticos, entre outros. Esse crescimento se deve as razões ambientais (uma vez que se utiliza água como fase contínua desta reação), também a versatilidade e a capacidade de produzir látex com diferentes propriedades para diferentes aplicações. Polímeros em emulsão são produtos por processo, isto é, suas propriedades são definidas durante a polimerização. Por isso, é importante o adequado monitoramento da reação de modo a permitir o controle das propriedades desejadas. A técnica de espectroscopia na região do infravermelho próximo (NIR), combinada com o uso de fibras óticas, é muito promissora para o monitoramento multivariável, em linha e em tempo real do processo de polimerização. O objetivo deste trabalho foi o de estudar o uso de espectroscopia NIR para o monitoramento em linha e em tempo real das concentrações de monômero e de não- voláteis (conhecido também como teor de sólidos) e da evolução do tamanho médio das partículas de látex (Dp) durante a reação de polimerização em emulsão de metacrilato de metila (MMA), em escala de laboratório e processo semi-batelada. Os modelos de calibração para estas variáveis foram obtidos experimentalmente empregando o método de regressão por mínimos quadrados parciais, PLS. Os resultados obtidos confirmaram algumas regiões espectrais do NIR indicadas em literatura como sendo adequadas na predição de monômero e Dp e revelaram -1 comportamentos espectrais ainda não explicados na região entre 10.475 e 13.000 cm , relacionados às variações no tamanho das partículas. Os resultados mostram também que é possível monitorar em linha e em tempo real a evolução do Dp e dos teores de monômero (MMA) e de não voláteis, simultaneamente em um único instrumento, utilizando modelos de calibração com bandas espectrais e pré-tratamentos distintos. / Emulsion polymerization is a largely and increasingly used technique in industrial production of paints, resins, plastics among others. This increase is due to environmental reasons (since water, rather than organic solvents is used as dispersing medium), as well as to the versatility and capacity of producing products with different properties for different applications. Emulsion polymers are products by process, i.e., the properties are mainly defined during the polymerization process. Thus, the adequate process monitoring is important for achieving the target properties. The NIR spectroscopy combined with optical fibers is a promising technique for the task of multivariable, real-time, in-line monitoring of polymerization processes. The aim of this work is the study of use of NIR spectroscopy for in-line, real time monitoring of the monomer and solids content, as well as the evolution of average size of the polymer particles (Dp), during semi-batch emulsion polymerization of methyl methacrylate in laboratory reactor. The calibration models for each of the monitored variables were obtained by applying the partial least squares regression method (PLS). The results confirmed that some NIR spectral ranges recommended in the literature are appropriate for the prediction of monomer content and Dp, and that there are spectral -1 . The results behaviors not yet explained in the region between 10475 and 13000cm also show that the in-line, the changes in Dp, monomer and polymer content can be simultaneously monitored in-line and in real time by NIR spectroscopy by using calibration models based on adequate spectral regions and distinct data pretreatments.

Neste trabalho estudou-se o processo de coplimerização em emulsão de estireno e acrilato de butila em processo semicontínuo onde o produto final é um látice com alto teor de sólidos. Foi realizada uma série de experimentos de copolimerização em emulsão em um reator de vidro, empregando receitas com teores de sólidos na faixa de 50 a 64% em massa. Foram estudados os seguintes fatores: teor de sólidos, teor de ácido acrílico, teor de emulsificantes e tempo de adição dos monômeros. Os efeitos estudados são avaliados principalmente em termos de conversão, diâmetro médio das partículas, concentração de partículas, número médio de radicais por partícula, taxa de polimerização, viscosidade e fração de coágulos. Também se avaliou a distribuição de tamanhos de partículas para o processo. Utilizando informações experimentais e da literatura, foi aplicado um modelo matemático para o processo, com razoável adequação aos dados experimentais. / The aim of this work was the study of the high solid contents emulsion copolymerization of styrene and butyl acrylate in semi-batch process. Copolymerization reactions were undertaken in a glass reactor, and recipes with solid contents up to 64 wt.% were used. Were evaluated the effects of: solid contents on recipe, amounts of acrylic acid and surfactants on recipe and monomer feeding time. The effects were evaluated in terms of conversion, particle mean diameter, and particle concentration, average number of radicals per particle, polymerization rate, viscosity and coagulum content. It was performed a characterization of the particle size distribution for this process. Using experimental observations and literature information, it was applied a mathematical model for this process, with satisfactory agreement with experimental data.

Carbohydrates on the cell surface conjugates to proteins and lipids and participates in biological processes as glycoconjugates. Carbohydrate functionalized nanoparticles (glyconanoparticles) constitute a good bio-mimetic model of carbohydrate presentation at the cell surface and are currently centered on many glycobiological and biomedical applications. The most of the applications have been reported using gold glyconanoparticles. A brief review of gold glyconanoparticles and some of their applications will be discussed in Chapter I. Although metallic, semiconductor and magnetic glyconanoparticles have been reported, no polyacrylate glyconanoparticles have yet to be described. Chapter II describes the first preparation of carbohydrate functionalized polymer nanoparticles by microemulsion polymerization and their characterization using scanning electron microscopy, dynamic light scattering and 1H NMR spectroscopy. This methodology can generate a large number of furanose and pyranose nanoparticle derivatives with an average particle size of around 40 nm with the protected carbohydrate hydroxyl functionality as acetyl or dimethylacetal groups. Formation of larger glyconanoparticles of around 80 nm with 3-O-acryloyl-D-glucose and 5-O-acryloyl-1-methoxy-beta-D-ribofuranose reveals the influence of free hydroxyl groups in the monomer on the particle size during polymerization, a feature which is also apparently dependent on the amount of carbohydrate in the matrix. Preparation of glyconanoparticle antibiotics, or glyconanobiotics, by microemulsion of antibiotic-conjugated carbohydrate monomers demonstrates for the first time the use of glyconanoparticles as drug delivery vehicles in Chapter III. The conjugation of an acrylated hydrophobic carbohydrate moiety to the lipophilic antibiotic makes it even more lipophilic and suitable as a co-monomer in microemulsion polymerization with styrene/butyl acrylate. Novel carbohydrate-based acrylated acyl chlorides synthesized from glucose afford antibiotic monomers with enhanced lipophilicity in a one step procedure. These drug monomers and the corresponding glyconanobiotics prepared by conjugating antibiotics such as N-thiolated-beta-lactam, ciprofloxacin, and penicillin shows biological activity against S. aureus, MRSA and B. anthracis microbes. Glyconanoparticles prepared by microemulsion polymerization of 3-O-acryloyl-D-glucose and styrene/butyl acrylate may be potentially used as recognition units in carbohydrate ligand mediated targeted drug delivery. The binding capability of the surface-exposed carbohydrates on the nanoparticle can be detected by fluorescence spectroscopy utilizing pyranine and 4,4'-N,N-bis(benzyl-2-boronic acid)-bipyridinium dibromide as described in Chapter IV.

Doctor of Philosophy / The kinetics of electrosterically stabilized emulsion systems was studied. The aim of this was to understand the impact that steric and electrosteric stabilizers have on the kinetics of particle growth and particle formation in the area of emulsion polymerization. The well-established mechanisms that govern these processes for emulsions stabilized by conventional low molecular weight surfactants were used as a reference point for comparative purposes. Model latexes were synthesized that comprised of a poly(styrene) core stabilized by a corona of poly(acrylic acid). The advent of successful controlled radical polymerization techniques in heterogeneous media (via RAFT polymerization) allowed for latexes to be synthesized under molecular weight control. For the first time, the degree of polymerization of the stabilizing block on the particle surface was able to be controlled and verified experimentally using mass spectrometry techniques. Three latexes were made with different average degrees of polymerization of the stabilizing block; five, ten and twenty monomer units respectively. A methodology was developed to remove the RAFT functionality from the polymer chains present in the emulsion while retaining the desired particle morphology. Oxidation with tertbutylhydroperoxide (TBHP) was proven to be successful at eliminating the living character provided by the thiocarbonyl end-group. Extensive dialysis and cleaning of the latex was performed to ensure no residual TBHP or reaction by-products remained. Latexes with poly(styrene) cores were chosen for this work as poly(n-butyl acrylate) latexes were shown to be influenced by chain transfer to polymer, providing an additional kinetic complication. The three electrosterically stabilized emulsions were used as seed latexes in carefully designed kinetic experiments to measure the rate of polymerization as a function of time. Two independent techniques (chemically initiated dilatometry and γ-relaxation dilatometry) were used to measure the rate coefficients of radical entry (ρ) and exit (k) in these systems – the two parameters that essentially govern the rate of particle growth. The latexes were chosen such that they satisfied ‘zero-one’ conditions (i.e. that any given latex particle contains at most one growing radical at any given time) in order to simplify data analysis. Three different chemical initiators were used, each yielding a radical with a different electric charge. Results from γ-relaxation experiments demonstrated that the three electrosterically stabilized latexes gave very long relaxation times when removed from the radiation source, ultimately yielding very small k values. These values were up to a factor of 10 smaller than that predicted by the ‘transfer-diffusion’ model for exit for particles of that size. This reduction was attributed to a ‘restricted diffusion’ effect, where the exiting monomeric radical has to diffuse through a dense layer of polymer on the particle surface, where its mobility will be restricted. Modification of the Smoluchowski equation for diffusion-controlled adsorption/desorption to account for this postulate led to the development of a model that gave excellent semi-quantitative agreement with experiment. Chemically initiated dilatometric experiments (using three different types of initiator) gave the unusual result of very low reaction rates and low steady-state values of 'nbar', the average number of radicals per particle. Using the standard kinetic equations for styrene-based systems (where it is assumed that an exited monomeric radical undergoes re-entry), this led to the calculation of impossibly small values of the entry rate coefficient ρ (far below any background or ‘thermal’polymerization rate). However upon removing the assumption of re-entry and assuming that exited radicals undergo termination, the obtained values of ρ were in almost perfect agreement with the values predicted from the ‘control by aqueous phase growth’ entry mechanism. This unexpected result was attributed to chemical reaction with the poly(acrylic acid) stabilizers through chain transfer to polymer (via hydrogen-atom abstraction). This postulate was verified by separate experiments that demonstrated that poly(acrylic acid) could act as a reasonably efficient chain transfer agent for styrene polymerization. The addition of poly(acrylic acid) to the aqueous phase of a conventionally stabilized emulsion also led to the rate reduction seen previously. NMR experiments demonstrated the existence of poly(acrylic acid-graft-styrene), which could only be formed through termination of a poly(styrene) chain with a poly(acrylic acid) chain bearing a mid-chain radical (as the product of a chain transfer reaction). These additional terms of transfer and termination were included in the governing kinetic equations of emulsion systems (the Smith-Ewart equations) to develop a model to account for the behaviour of electrosterically stabilized latexes. The ultimate fate of an exiting radical was now shown to be a competition between fates; successful desorption into the aqueous phase, or chemical reaction (through transfer or termination) within the hairy layer. These additional terms were shown to significantly reduce the theoretical value of nbar, and were in excellent agreement with experiment. For small electrosterically stabilized particles with a densely packed ‘hairy layer,’ it was seen that transfer/termination is the dominant loss mechanism as opposed to desorption. The developed model showed that as the particle size was increased, the dominant loss mechanism once again became successful desorption into the aqueous phase. The model was shown to give excellent agreement with experimental data from ‘uncontrolled’ emulsion systems. To explain the highly unusual secondary nucleation behaviour seen in systems such as these, it was postulated that beta-scission of a poly(acrylic acid) chain bearing a mid-chain radical is an important mechanistic step in the nucleation mechanisms of these systems. Modelling (both steady-state and time-dependent) gave good agreement with experiment with a minimal number of adjustable parameters. Theory (and supporting experimental evidence) demonstrated that this nucleation mechanism is only significant at high particle numbers; under other conditions the well-known ‘homogeneous nucleation’ mechanism is once again dominant.

For more than 70 years, understanding of the mechanism of particle nucleation in emulsion polymerization has been one of the most challenging issues in heterophase polymerization research. Within this work a comprehensive experimental study of particle nucleation in emulsion polymerization of styrene at 70 °C and variety of conditions has been performed. To follow the onset of nucleation, on-line conductivity measurements were applied. This technique is highly sensitive to the mobility of conducting species and hence, it can be employed to follow aggregation processes leading to particle formation. On the other hand, by recording the optical transmission (turbidity) of the reaction mixture particle growth was followed. Complementary to the on-line investigations, off-line characterizations of the particle morphology and the molecular weight have been performed. The aim was to achieve a better insight in the processes taking place after starting the reaction via particle nucleation until formation of colloidally stable latex particles. With this experimental protocol the initial period of styrene emulsion polymerization in the absence as well as in the presence of various surfactants (concentrations above and below the critical micellization concentration) and also in the presence of seed particles has been investigated. Ionic and non-ionic initiators (hydrophilic and hydrophobic types) have been applied to start the polymerizations. Following the above algorithm, experimental evidence has been obtained showing the possibility of performing surfactant-free emulsion polymerization of styrene with oil-soluble initiators. The duration of the pre-nucleation period (that is the time between starting the polymerization and nucleation) can be precisely adjusted with the initiator hydrophobicity, the equilibration time of styrene in water, and the surfactant concentration. Spontaneous emulsification of monomer in water, as soon as both phases are brought into contact, is a key factor to explain the experimental results. The equilibration time of monomer in water as well as the type and concentration of other materials in water (surfactants, seed particles, etc.) control the formation rate and the size of the emulsified droplets and thus, have a strong influence on the particle nucleation and the particle morphology. One of the main tasks was to investigate the effect of surfactant molecules and especially micelles on the nucleation mechanism. Experimental results revealed that in the presence of emulsifier micelles the conductivity pattern does not change essentially. This means that the presence of emulsifiers does not change the mechanism of particle formation qualitatively. However, surfactants assist in the nucleation process as they lower the activation free energy of particle formation. Contrary, seed particles influence particle nucleation, substantially. In the presence of seed particles above a critical volume fraction the formation of new particles can be suppressed. However, micelles and seed particles as absorbers exhibit a common behavior under conditions where monomer equilibration is not allowed. Results prove that the nucleation mechanism comprises the initiation of water soluble oligomers in the aqueous phase followed by their aggregation. The process is heterogeneous in nature due to the presence of monomer droplets. / Polymere dominieren unsere Welt. Die natürlich vorkommenden Polymeren, wie Proteine, Polynukleotide, und Polysaccharide, sind nötig um das Leben zu erhalten. Ebenso wichtig sind die kommerziell erhältlichen Makromoleküle. Beides sind Bausteine, um Materialien zu konstruieren, welche man in beiden Welten finden kann- der natürlichen und der „Mensch-gemachten“ Welt. Unter den verschiedenen Polymerisationsmethoden hat sich die Emulsions-polymerisation zu einem weit verbreiteten Prozess entwickelt. Die Emulsionspolymerisation ist ein einzigartiger Polymerisationsprozess, bei dem ein Monomer oder ein Gemisch von Monomeren in einem wässrigen Medium polymerisiert wird. Dabei entsteht eine Dispersion von Polymeren, welche auch als Latex bezeichnet wird. Derzeit werden mehrere Millionen Tonnen von synthetischen Latices mit Hilfe der Emulsionspolymerisation hergestellt. Diese finden zum Beispiel Verwendung als synthetische Gummi, Latexschaum, Latexfarben, Papierbeschichtungen und Klebstoffen. Außerdem findet man sie auch bei Spezialanwendungen, wie Diagnosetests, Pharmakotherapien und chromatographischen Trennmethoden. Trotz der Vielzahl von industriellen Anwendungen, sollten all jenen, die sich mit Emulsionspolymerisation beschäftigen, den wissenschaftlichen und technologischen Herausforderungen, die sich stellen, bewusst sein. Die wichtigsten Fragen beim Umgang mit der Emulsionspolymerisation beinhalten das Verständnis des Prozesses der Partikelbildung und des Partikelwachstums. Die vorliegende Dissertation beschäftigt sich mit der Frage der Keimbildungs-etappe in Emulsionspolymerisationen. Die Untersuchungen wurden mit Hilfe eines on-line Leitfähigkeitsmessverfahren sowie einigen off-line analytischen Experimenten durchgeführt. Basierend auf den klaren experimentellen Daten, wurde ein besserer Einblick in die tatsächlichen Zustände des Polymerisationssystems, von der Zeit der neu geboren Kerne bis zu endgültig stabilisierten Teilchen, gewonnen.

Heterophase polymerization is a technique widely used for the synthesis of high performance polymeric materials with applications including paints, inks, adhesives, synthetic rubber, biomedical applications and many others. Due to the heterogeneous nature of the process, many different relevant length and time scales can be identified. Each of these scales has a direct influence on the kinetics of polymerization and on the physicochemical and performance properties of the final product. Therefore, from the point of view of product and process design and optimization, the understanding of each of these relevant scales and their integration into one single model is a very promising route for reducing the time-to-market in the development of new products, for increasing the productivity and profitability of existing processes, and for designing products with improved performance or cost/performance ratio. The process considered is the synthesis of structured or composite polymer particles by multi-stage seeded emulsion polymerization. This type of process is used for the preparation of high performance materials where a synergistic behavior of two or more different types of polymers is obtained. Some examples include the synthesis of core-shell or multilayered particles for improved impact strength materials and for high resistance coatings and adhesives. The kinetics of the most relevant events taking place in an emulsion polymerization process has been investigated using suitable numerical simulation techniques at their corresponding time and length scales. These methods, which include Molecular Dynamics (MD) simulation, Brownian Dynamics (BD) simulation and kinetic Monte Carlo (kMC) simulation, have been found to be very powerful and highly useful for gaining a deeper insight and achieving a better understanding and a more accurate description of all phenomena involved in emulsion polymerization processes, and can be potentially extended to investigate any type of heterogeneous process. The novel approach of using these kinetic-based numerical simulation methods can be regarded as a complement to the traditional thermodynamic-based macroscopic description of emulsion polymerization. The particular events investigated include molecular diffusion, diffusion-controlled polymerization reactions, particle formation, absorption/desorption of radicals and monomer, and the colloidal aggregation of polymer particles. Using BD simulation it was possible to precisely determine the kinetics of absorption/desorption of molecular species by polymer particles, and to simulate the colloidal aggregation of polymer particles. For diluted systems, a very good agreement between BD simulation and the classical theory developed by Smoluchowski was obtained. However, for concentrated systems, significant deviations from the ideal behavior predicted by Smoluchowski were evidenced. BD simulation was found to be a very valuable tool for the investigation of emulsion polymerization processes especially when the spatial and geometrical complexity of the system cannot be neglected, as is the case of concentrated dispersions, non-spherical particles, structured polymer particles, particles with non-uniform monomer concentration, and so on. In addition, BD simulation was used to describe non-equilibrium monomer swelling kinetics, which is not possible using the traditional thermodynamic approach because it is only valid for systems at equilibrium. The description of diffusion-controlled polymerization reactions was successfully achieved using a new stochastic algorithm for the kMC simulation of imperfectly mixed systems (SSA-IM). In contrast to the traditional stochastic simulation algorithm (SSA) and the deterministic rate of reaction equations, instead of assuming perfect mixing in the whole reactor, the new SSA-IM determines the volume perfectly mixed between two consecutive reactions as a function of the diffusion coefficient of the reacting species. Using this approach it was possible to describe, using a single set of kinetic parameters, typical mass transfer limitations effects during a free radical batch polymerization such as the cage effect, the gel effect and the glass effect. Using multiscale integration it was possible to investigate the formation of secondary particles during the seeded emulsion polymerization of vinyl acetate over a polystyrene seed. Three different cases of radical generation were considered: generation of radicals by thermal decomposition of water-soluble initiating compounds, generation of radicals by a redox reaction at the surface of the particles, and generation of radicals by thermal decomposition of surface-active initiators "inisurfs" attached to the surface of the particles. The simulation results demonstrated the satisfactory reduction in secondary particles formation achieved when the locus of radical generation is controlled close to the particles surface. / Eine der industriell am meisten verwendeten Methoden zur Herstellung von Hochleistungspolymeren ist die Heterophasenpolymerisation. Industriell von besonderer Bedeutung ist die sogenannte Saatemulsionspolymerisation bei der kleine Saatteilchen durch die sequentielle Zugabe von weiteren Monomeren gezielt modifiziert werden, um Kompositpolymerteilchen mit den gewünschten mechanischen und chemischen Gebrauchseigenschaften herzustellen. Ein häufig auftretendes Problem während dieser Art der Heterophasenpolymerisation ist die Bildung von neuen, kleinen Teilchen im Polymerisationsverlauf. Diese sogenannte sekundäre Teilchenbildung muss vermieden werden, da sie die Herstellung der gewünschten Teilchen mit den angestrebten Eigenschaften verhindert. Ein spezieller Fall der Saatemulsionspolymerisation ist die Kombination von Vinylacetat als Monomer, das auf Saatteilchen aus Polystyrol polymerisieren soll. Die Unterdrückung der Teilchenneubildung ist in diesem Beispiel besonders schwierig, da Vinylacetat eine sehr hohe Wasserlöslichkeit besitzt. In der vorliegenden Arbeit wurden zur Lösung der Aufgabenstellung verschiedene numerische Simulierungsalgorithmen verwendet, die entsprechend den charakteristischen Längen- und Zeitskalen der im Verlauf der Polymerisation ablaufenden Prozesse ausgewählt wurden, um die passenden Bedingungen für die Unterdrückung der sekundären Teilchenbildung zu finden. Die verwendeten numerischen Methoden umfassen Molekulare Dynamik Simulationen, die benutzt werden, um molekulare Bewegungen zu berechnen; Brownsche Dynamik Simulationen, die benutzt werden, um die zufälligen Bewegungen der kolloidalen Teilchen und der molekularen Spezies zu beschreiben, und kinetische Monte Carlo Simulationen, die das zufällige Auftreten von individuellen physikalischen oder chemischen Ereignissen modellieren. Durch die Kombination dieser Methoden ist es möglich, alle für die Beschreibung der Polymerisation relevanten Phänomene zu berücksichtigen. Damit können nicht nur die Reaktionsgeschwindigkeit und die Produktivität des Prozesses simuliert werden sondern auch Aussagen bezüglich der physikalischen und chemischen Eigenschaften des Produktes sowie den Applikationseigenschaften getroffen werden. In dieser Arbeit wurden zum ersten Mal Modelle für die unterschiedlichen Längen- und Zeitskalen bei Heterophasenpolymerisationen entwickelt und erfolgreich zur Modellierung des Prozesses angewendet. Die Ergebnisse führten zu bedeutenden Verbesserungen der Theorie von Emulsionspolymerisationen insbesondere für die Beschreibung des Massenaustausches zwischen den Phasen (bspw. Radikaleintritt in und Radikalaustritt aus die Polymerteilchen), der Bildung von neuen Teilchen, und der Polymerisationskinetik unter den heterogenen Reaktionsbedingungen mit uneinheitlicher Durchmischung.

This thesis aims to improve the performance of latex-based pressure-sensitive adhesives (PSAs). PSA performance is usually evaluated by tack, peel strength and shear strength. Tack and peel strength characterize a PSA’s bonding strength to a substrate while shear strength reflects a PSA’s capability to resist shear deformation. In general, increasing shear strength leads to a decrease in tack and peel strength. While there are several commercial PSA synthesis methods, the two most important methods consist of either solvent-based or latex-based techniques. While latex-based PSAs are more environmentally compliant than solvent-based PSAs, they tend to have much lower shear strength, at similar tack and peel strength levels. Therefore, the goal in this thesis was to greatly improve the shear strength of latex-based PSAs at little to no sacrifice to tack and peel strength. In this study, controlling the polymer microstructure of latexes or their corresponding PSA films was used as the main method for improving the PSA performance. The research was sub-divided into four parts. First, the influence of chain transfer agent (CTA) and cross-linker on latex polymer microstructure was studied via seeded semi-batch emulsion polymerization of butyl acrylate (BA) and methyl methacrylate (MMA). Three techniques were used to produce the latexes: (1) adding CTA only, (2) adding cross-linker only, and (3) adding both CTA and cross-linker. It was found that using CTA and cross-linker simultaneously allows one to expand the range of latex microstructural possibilities. For example, latexes with similar gel contents but different Mc (molecular weight between cross-links) and Mw (molecular weight of sol polymers) could be produced if CTA and cross-linker concentration are both increased. However, for the corresponding PSAs with similar gel contents, the relationship between their polymer microstructure and performance was difficult to establish as almost all of the medium and high gel content PSAs showed very low tack and peel strength as well as extremely large shear strength readings. In the second part of this thesis, in order to improve the tack and peel strength of medium and high gel content PSAs, the monomer composition and emulsifier concentration were varied. It was found that changing the monomer mixture from BA/MMA to BA/acrylic acid (AA)/2-hydroxyethyl methacrylate (HEMA) while simultaneously decreasing emulsifier concentration dramatically improved the corresponding PSAs’ shear strength as well as tack and peel strength. The addition of polar groups to the PSA increased its cohesive strength due to the presence of strong hydrogen bonding; meanwhile, PSA films’ surface tension increased. In the third part, two series of BA/AA/HEMA latexes were generated by varying the amounts of CTA either in the absence or presence of cross-linker. The latexes produced in the absence of cross-linker exhibited significantly larger Mc and Mw compared to their counterparts with similar gel contents prepared with cross-linker. The PSAs with the larger Mc and Mw showed much larger shear strengths due to improved entanglements between the polymer chains. In the final part of the thesis, the performance of the BA/AA/HEMA PSAs was further improved by post-heating. Compared with original latex-based PSAs with similar gel contents, heat-treated PSAs showed not only significantly improved shear strengths, but also much larger tack and peel strengths. The different shear strengths were related to the PSAs’ gel structures, which were discrete in the original PSAs but continuous in the heat-treated PSAs. The improved tack and peel strengths were related to the PSA films’ surface smoothness. During the post-heating process, the PSA polymer flowed, resulting in much smoother surfaces than the original PSA films. In addition, the effect of post-heating was related to the polymer microstructure of the untreated PSAs. Decreasing the amount of very small or very big polymers or simultaneously increasing Mc and Mw could lead to post-treated PSAs with significantly better performance. Moreover, it was found that by optimizing the polymer microstructure of the original latex-based PSAs, it was possible to obtain a treated PSA with similar or even better performance than a solvent-based PSA with similar polymer microstructure. Our original objective was surpassed: in two cases, not only was shear strength greatly improved, but so were tack and peel strength due to the simultaneous modification of PSA bulk and surface properties.

This thesis aims to improve the performance of latex-based pressure-sensitive adhesives (PSAs). PSA performance is usually evaluated by tack, peel strength and shear strength. Tack and peel strength characterize a PSA’s bonding strength to a substrate while shear strength reflects a PSA’s capability to resist shear deformation. In general, increasing shear strength leads to a decrease in tack and peel strength. While there are several commercial PSA synthesis methods, the two most important methods consist of either solvent-based or latex-based techniques. While latex-based PSAs are more environmentally compliant than solvent-based PSAs, they tend to have much lower shear strength, at similar tack and peel strength levels. Therefore, the goal in this thesis was to greatly improve the shear strength of latex-based PSAs at little to no sacrifice to tack and peel strength. In this study, controlling the polymer microstructure of latexes or their corresponding PSA films was used as the main method for improving the PSA performance. The research was sub-divided into four parts. First, the influence of chain transfer agent (CTA) and cross-linker on latex polymer microstructure was studied via seeded semi-batch emulsion polymerization of butyl acrylate (BA) and methyl methacrylate (MMA). Three techniques were used to produce the latexes: (1) adding CTA only, (2) adding cross-linker only, and (3) adding both CTA and cross-linker. It was found that using CTA and cross-linker simultaneously allows one to expand the range of latex microstructural possibilities. For example, latexes with similar gel contents but different Mc (molecular weight between cross-links) and Mw (molecular weight of sol polymers) could be produced if CTA and cross-linker concentration are both increased. However, for the corresponding PSAs with similar gel contents, the relationship between their polymer microstructure and performance was difficult to establish as almost all of the medium and high gel content PSAs showed very low tack and peel strength as well as extremely large shear strength readings. In the second part of this thesis, in order to improve the tack and peel strength of medium and high gel content PSAs, the monomer composition and emulsifier concentration were varied. It was found that changing the monomer mixture from BA/MMA to BA/acrylic acid (AA)/2-hydroxyethyl methacrylate (HEMA) while simultaneously decreasing emulsifier concentration dramatically improved the corresponding PSAs’ shear strength as well as tack and peel strength. The addition of polar groups to the PSA increased its cohesive strength due to the presence of strong hydrogen bonding; meanwhile, PSA films’ surface tension increased. In the third part, two series of BA/AA/HEMA latexes were generated by varying the amounts of CTA either in the absence or presence of cross-linker. The latexes produced in the absence of cross-linker exhibited significantly larger Mc and Mw compared to their counterparts with similar gel contents prepared with cross-linker. The PSAs with the larger Mc and Mw showed much larger shear strengths due to improved entanglements between the polymer chains. In the final part of the thesis, the performance of the BA/AA/HEMA PSAs was further improved by post-heating. Compared with original latex-based PSAs with similar gel contents, heat-treated PSAs showed not only significantly improved shear strengths, but also much larger tack and peel strengths. The different shear strengths were related to the PSAs’ gel structures, which were discrete in the original PSAs but continuous in the heat-treated PSAs. The improved tack and peel strengths were related to the PSA films’ surface smoothness. During the post-heating process, the PSA polymer flowed, resulting in much smoother surfaces than the original PSA films. In addition, the effect of post-heating was related to the polymer microstructure of the untreated PSAs. Decreasing the amount of very small or very big polymers or simultaneously increasing Mc and Mw could lead to post-treated PSAs with significantly better performance. Moreover, it was found that by optimizing the polymer microstructure of the original latex-based PSAs, it was possible to obtain a treated PSA with similar or even better performance than a solvent-based PSA with similar polymer microstructure. Our original objective was surpassed: in two cases, not only was shear strength greatly improved, but so were tack and peel strength due to the simultaneous modification of PSA bulk and surface properties.

Commodity and specialty-grade rubbers, such as styrene-butadiene (SBR) or nitrile-butadiene (NBR), are industrially produced in large trains of continuous reactors using an emulsion polymerization process. Both SBR and NBR systems are largely unstudied. Furthermore, the studies that have been published on NBR have been typically limited to issues concerning the characteristics of the product behaviour (i.e. oil/fuel resistance, tensile strength, hardness, compression set). In this work a detailed mathematical model has been developed in order to simulate the industrial production of NBR via emulsion copolymerization of acrylonitrile (AN) and butadiene (Bd) in batch, continuous and trains of continuous reactors. Model predictions include monomer conversion, polymerization rate, copolymer composition, number- and weight-average molecular weights, tri- and tetra-functional branching frequencies, and the number and average size of polymer latex particles. NBR is typically produced at low temperatures (5 to 10 degrees C) using a redox initiation system to generate free radicals. The system is typically composed of three phases, water, polymer particles, and monomer. Surfactants and electrolytes are used to stabilize the particle and monomer phases as polymerization proceeds. Of particular industrial importance, in today's world of tailor-made products, is detailed control over the polymerization reaction. Such control requires a deep understanding of the influence of various reactant feed rates and reactor operating conditions on the process response. In particular, policies to minimize copolymer composition drift and to control molecular weight, polydispersity and chain branching at desirable levels. The model is cast in a dynamic form using ordinary differential equations to describe the change of each species, the average number of particles, total average polymer volume, and the first three leading moments of the molecular weight distribution. With a multiphase system it is necessary to determine the concentration of each component in each phase. For this, a constant partition coefficient approach was adopted, as opposed to a purely thermodynamic approach. Particle generation was modelled considering both micellar and homogeneous mechanisms. Model parameters were obtained from the open literature or arrived at after sensitivity analysis. Simulations starting the reactors full of water, feeding all ingredients to the first reactor and using an average residence time of 60 minutes revealed considerable copolymer drift starting in the forth reactor (33% conversion), and heightened molecular weights and chain branching once the monomer phase disappeared (50% conversion). Further simulations revealed that both copolymer drift and the growth of molecular weight and branching could be controlled through additional feed streams of AN and chain transfer agent to downstream reactors. Furthermore, polymer productivity could be increased by appropriately splitting the total monomer feed between the first couple of reactors in the train.