The Synthesis of Sulfonated Polymers by Free Radical Copolymerization. Poly(butadiene-co-Sodium Styrene Sulfonate) R. A. WEISS and R. D. LUNDBERG, Corporate Research Science Laboratories, Exxon Research and Engineering Company, P.O. Box 45, Linden, New Jersey 07036, and A. WERNER, Princeton Polymer Laboratories, 501 Princeton Road, Plainsboro, New Jersey 08536 Synopsis The copolymerization of butadiene with sodium styrene sulfonate was studied and the copolymer products characterized. In general these copolymers contain 0.5-4 mole % of sulfonated monomer. The effects of the following reaction variables are described: emulsifier type and concentration, monomers feed ratio, chain transfer agent concentration, and reaction conversion. The products were heterogeneous with regard to composition, molecular weight, and solubility behavior. Copolymers prepared under certain conditions exhibited strong intermolecular interactions derived from associations of the ionic species as observed in other ionomers. INTRODUCTION The modification of hydrocarbon polymers by the inclusion of salt groups has received considerable attention in recent years. Specifically, when a modest number, for example, less than 10 mole %, of ionic groups is attached to a polymer backbone, the intermolecular associations of the ionic species that result develop properties analogous to those of a crosslinked po1ymer.l An important distinction, however, exists between an “ionic crosslink” and a covalent crosslink the ionic crosslink is reversible; that is, the ionic associations can be so weakened by the application of heat or the introduction of specific low molecular weight polar “plasticizers”2 that under suitable conditions an ionomer can behave as if it were not crosslinked and under other conditions as if it were. There are basically two methods of preparing ionomers: (1) by grafting an ionic substituent onto a preformed polymer and (2) by copolymerization of a hydrocarbon monomer and an unsaturated acid or salt. The second method has been used extensively in the preparation of carboxylate ionomers? whereas postreactions have largely been used to prepare sulf~nate-ionomers.~~~ A comprehensive discussion of these materials can be found in several monog r a p h ~ ’and ? ~ review articles6 and is not treated here. The purpose of this article is to describe the preparation of a sulfonate-ionomer by the copolymerization of butadiene and sodium styrene sulfonate ( S S S ) . In particular, the effects of several copolymerization parameters on the polymer products are discussed, with special emphasis on the “ionic” or “nonionic” character of these products. Journal of Polymer Science: Polymer Chemistry Edition, Vol. 18,3427-3439 (1980) 0 1980 John Wiley & Sons, Inc. 0360-6376/80/0018-3427$01.30 3428 WEISS, LUNDBERG, AND WERNER PRIOR ART Although copolymerization reactions of vinyl and diene hydrocarbon monomers with an unsaturated sulfonic acid derivative have been reported in the literature, relatively few studies have been concerned with the preparation of copolymers that contain low concentrations of metal sulfonate groups. Most of the prior art in this area considered the incorporation of metal-sulfonatecontaining monomers into polymers in order to stabilize latices derived from free radical polymerizations or to improve the dyeability of polymer fibers.7 No significant efforts have been directed, however, at the isolation and characterization of the resulting ion-containing polymer, nor have any concerted efforts been made to control the degree of sulfonate group incorporation in these copolymers. For the specific case of butadiene its copolymerization with various vinyl sulfonate esters has been described by Marvel et a1.: although these materials were not converted to the salt. A patent assigned to Teijin Ltd. in 19729 described the preparation of polybutadiene latices of large particle sizes by polymerizing butadiene in the presence of sodium methallyl sulfonate, but these latices were used as intermediates in the preparation of ABS resins and not characterized as ionomers. EXPERIMENTAL Materials The reagents used in these experiments are listed in Table I. With the exception of the butadiene all materials were used as received; butadiene was evaporated and condensed in a trap cooled with dry ice and acetone. The water used in the polymerizations was distilled and boiled before use. TABLE I Reagents Reagent Monomers Butadiene Sodium Styrene Sulfonate Surfactants Pluronic L62-LF (polyol) Pluronic F-68 (polyol) Tween 80 (sorbitan monooleate) Clearate (soya-lecithin derivative) WAQE (sodium lauryl sulfate) Redox Initiators Triethylenetetramine (TETA) Diisopropylbenzene hydroperoxide (DIBHT) Chain Transfer Agent Dodecanethiol Buffer Na4P20~10H20 SuDDlier Matheson Gas Products Columbia Organic Chemicals BASF Wyandotte BASF Wyandotte ICI W. A. Cleary Du Pont Union Carbide Pfaltz and Bauer Matheson, Coleman, and Bell Mallinckrodt SYNTHESIS OF SULFONATED POLYMERS 3429 Polymerizations The reaction vessel consisted of a beverage bottle sealed with a crown-type screw cap that contained a 3/32-in. hole in the center and a nitrile rubber gasket 1/32 in. thick. An excess of condensed butadiene monomer was poured into a reaction bottle that contained the other reagents (SSS,emulsifier, redox initiator, chain transfer agent, buffer, and water). Butadiene was then allowed to evaporate until the desired charge was reached, at which point the bottle was capped and placed in a constant-temperature bath equipped with a mechanical bottle shaker. At the end of the reaction a methanolic solution of hydroquinone (shortstop) and 2,2’-methylene-bis(4-methyl-6-t-butyl phenol) (antioxidant) was injected with a hypodermic needle through the septum in the bottle cap. After the bottle was shaken for an additional 5-10 min to disperse the shortstop and antioxidant effectively, it was cooled in ice water and the cap was removed. The polymer was precipitated in methanol, which contained 0.05% antioxidant, washed until the supernatant liquid was clear, and dried under vacuum at 4OOC. The polymers were subsequently stored in glass jars covered with aluminum foil to minimize any ultraviolet (UV) degradation. The sulfur content of the copolymers were determined by Dietert sulfur analysis (ASTM D1552). Reduced viscosities a t 25OC were measured with a Ubbelohde capillary viscometer at a polymer concentration of 0.2 g/dl in a mixed solvent of 90%toluene and 10%methanol. RESULTS AND DISCUSSION Based on the substantial difference in the polarity of the two monomers, it is unlikely that the copolymerization of butadiene and SSS will behave as a conventional emulsion polymerization. Whereas in a conventional system the two comonomers reside within a single phase or have significant mutual solubility, in the butadiene-SSS system the SSS is contained predominantly in the aqueous phase. Because copolymerization does occur, it has been postulated that the reaction locus is the surface of the butadiene micelles.l0 This hypothesis suggests that SSS is a surfactant in this system; this is made clear in the discussion that follows. The mechanism of this copolymerization is complicated by the fact that, as SSS is consumed, not only does the comonomer concentration change but so does the surfactant concentration. Similarly, the solubility of the sulfonate monomer in the hydrocarbon phase is expected to be dependent on the composition of the swollen polymer particles and changes that occur during copolymerization may alter the particle morphology and the locus of polymerization. For these reasons the effects of conversion on the copolymer composition and molecular weight are expected to be more complex than is normal for an emulsion polymerization. The stability of the emulsion latex is also expected to influence the copolymer characteristics. In many of the reactions described here the latex became unstable a t moderate to high conversions and the presence of large agglomerated particles was observed. What effect this has on the product of these copolymerizations is not clear. This also raises the question whether these reactions actually proceed by an emulsion polymerization mechanism or are perhaps more WEISS, LUNDBERG, AND WERNER 3430 analogous to suspension polymerizations. These questions are beyond the scope of this initial program but are currently being considered in our laboratory. The incorporation of SSS in butadiene was confirmed by elemental analysis of the resulting polymers and by infrared (IR) spectroscopy. A typical IR spectrum of a butadiene-SSS copolymer is given in Figure 1and the absorption bands present at 1200,1130,1045, and 835 cm-' confirm the existence of SSS. The polybutadiene microstructure determined by IR corresponded to approximately 57% trans-l,4,18% cis-l,4, and 24% 1,2. Molecular weight is characterized in this article solely by the polymer-reduced viscosity in a mixed solvent system. Although it would be desirable to have a more complete description of the polymer molecular weight and molecular weight distribution, the presence of the small amount of ionic substituents in these materials render them unamenable to other molecular weight techniques; for example, gel permeation chromatography is complicated by adsorption of the sulfonated polymer on the gel p h a e and light scattering or osmometry analyses are complicated by the need to use mixed solvents to dissolve the ionomers. In the discussion that follows, the effects of various reaction variables on the copolymer composition, molecular weight, and solubility characteristics are described. Emulsifier Type and Concentration Both ionic and nonionic emulsifiers were evaluated in this study; their effect on the copolymer product is demonstrated in Table 11. For the nonionic emulsifiers studied, an optimum reaction rate was achieved when the HLB number* was 29. When the HLB of the surfactant was lower than 29, the conversion after w 0 z a l- I- 5z s I- s 3800 3400 3000 26002200 18003600140012001000 800 600 1 50 WAVENUMBERS Fig. 1. Infrared spectrum of butadiene-sodium styrene sulfonate copolymer (83-37), 0.61% sulfur. * HLB is an empirical measure of the hydrophilic-lipophilicbalance of a surface-active substance. A low number indicates lipophilic character and a high value, hydrophilic character. SYNTHESIS O F SULFONATED POLYMERS 120" I 0 0 0 r - m m m o 3 m m r - 3431 3432 WEISS, LUNDBERG, AND WERNER 20 hr decreased and for an emulsifier HLB of 7 no product was formed. Similarly, for an emulsifier HLB of 70 no polymerization occurred. A modest increase in SSS incorporation in the copolymer results when the HLB of the nonionic emulsifier is increased. A more substantial increase in the polymer molecular weight and ionic fraction of the copolymer product occurs when the HLB is increased from 15 to 29. The ionic fraction is defined here as a material that is insoluble in the hydrocarbon solvent, yet soluble in a more polar mixed solvent of hydrocarbon and alcohol. It has been demonstrated for sulfonated ethylene-propylene-diene terpolymers that insolubility in hydrocarbon solvents is due to the relatively strong intermolecular associations of the ionic species which can be disrupted by the addition of a polar cosolvent; for example, alcoh01.~ In sample 83-32 (HLB = 15) the ionic fraction is 4% of the nongel material, whereas for samples 83-37 and 97-7 (HLB = 29) the corresponding numbers are 41 and 68%. The disparity between the last two numbers demonstrates the complexities in the solubility behavior of these materials. Runs 83-37 and 97-7 were duplicate experiments, and except for the difference in the solubility characteristics, the reproducibility was excellent (e.g., conversion, molecular weight, and sulfur concentration). The amounts of ionic fraction, then, suggest that sample 83-32 is relatively nonionic, whereas samples 83-37 and 97-7 exhibit substantial ionic character. In ionic emulsifier, WAQE, the reaction rate was considerably less than for HLB-15 (Tween 80) or HLB-29 (Pluronic F-68) nonionic surfactants. The molecular weight was comparable to that achieved with Tween 80 and the SSS incorporation to that with Pluronic F-68. The solubility behavior of the products of duplicate experiments with ionic surfactant (experiments 97-5 and 97-11) were again substantially different; the reproducibility of all the other copolymer characteristics was good, however. In general, the ionic fraction appeared to be comparable to that achieved with Pluronic F-68. An interesting result occurred when SSS was used for both comonomer and surfactant (experiment 97-1). In this case the charge of SSS was doubled to conform more closely to the formulations used in the other experiments described in Table 11. No product was observed after 2 hr; after 7 hr the reaction mixture appeared to be a stable latex and after 33 hr the mixture was a homogeneous, smooth gel. The data in Table I1 indicate that the reaction rate was relatively slow and the molecular weight, relatively low. On the other hand, the SSS incorporation was twice that achieved with the other surfactants and the product was gel-free (100%soluble) with a substantial ionic fraction (34%). The fact that polymerization even occurred has a greater significance in light of the attempts to polymerize butadiene homopolymer with Tween 80 or Pluronic F-68 as the emulsifier. In these experiments no product was formed after 20 hr. In every case in which SSS was present, however, some polymerization took place. These results strongly suggest that SSS is present at the butadiene micelle. SSS Concentration Because SSS functions as an emulsifier in addition to being the comonomer, one might expect the concentration of the SSS in the charge to have an important effect on the product of the reaction; for example, an increase in SSS charge might be expected to increase the reaction rate by increasing the surfactant concen- SYNTHESIS OF SULFONATED POLYMERS 3433 tration and to increase the sulfonate incorporation by increasing the SSS/butadiene ratio. The effect of SSS concentration on the copolymerization was determined for three different surfactant systems: Tween 80 (nonionic, HLB = 15), Pluronic F-68 (nonionic, HLB = 29), and WAQE (ionic); the results are summarized in Table 111. With the exception of experiment 83-45,an increase in the SSS charge resulted in an increase in the reaction conversion. As explained above, this is most likely a consequence of the emulsifying capability of the SSS. The effect of increasing the SSS charge on the SSS incorporation is not, however, straightforward. In some instances an increase in the SSS feed concentration led to an increase in SSS incorporation, whereas in others a decrease resulted. Similarly, the copolymer molecular weight did not appear to be a simple function of the amount of SSS used. For the Tween 80 system molecular weight decreased with increasing SSS charge, and for the WAQE the molecular weight did not appear to be sensitive to the SSS charge. The polymer ionic fraction increased with SSS charge for the systems using Tween 80 and WAQE; when Pluronic F-68 was used the toluene-soluble fraction (nonionic fraction) decreased and the gel fraction increased. Because of the relatively high SSS content in the latter polymers, especially samples 83-48 and 97-16, it is not clear whether the gel fractions were covalently or physically crosslinked by intermolecular associations of the ionic groups. It is shown later in this article that the gel fractions of the butadiene-SSS copolymers were generally higher in sulfonate content than the soluble fractions, and in many instances the sulfonate content of the gel fraction exceeded 2 mole % (1.12%s). Chain Transfer Agent Concentration Chain transfer agents are often used in free-radical polymerizations to reduce the molecular weight of the polymer produced and to minimize crosslinking reactions. The latter was especially important in this study because of the difficulty of distinguishing between covalent crosslinking and a high level of ionic crosslinking. Similarly, very high molecular weight polymers were not desirable because under certain conditions these materials exhibit behavior analogous to a crosslinked polymer. The effects of dodecanethiol (chain transfer agent) concentration on the copolymerization products of this investigation are given in Table IV. The most important effect of increasing the dodecanethiol concentration was the expected one, a lowering of the apparent polymer molecular weight. The prefix, apparent, is stressed here in that the molecular weights inferred from the reduced viscosities of these polymers are influenced by inter- and intramolecular interactions of the ionic species which can in some instances affect the solution viscosities to a greater degree than the backbone molecular weight." It should also be emphasized that the reduced viscosities may reflect a fractionation of the copolymer by molecular weight or ionic interactions. As mentioned in the preceding section, the latter possibility is especially important for copolymers that contain a relatively high concentration of SSS; for example, more than 2 mole %. In general, the chain transfer agent concentration did not appear to affect the copolymer compositions significantly. a 20 44 44 - - 87 95 >lo0 >loo 85 39 66 100 100 100 92 38 29 62 78 64 75 30 67 86 59 29 15 27 26 99 74 - - 0 Mixed solvent Toluene 0 (9%) 0 0 8 62 71 38 0 22 36 - Gel ?red 2.1 2.3 0.79 0.46 1.0 1.0 1.1 - 1.6 0.8 - 0.61 0.57 1.44 1.92 0.80 0.64 0.46 - 0.44 0.99 - %S Reaction formulation: 38.8g butadiene, variable SSS, 4.6g emulsifier, 1.0g TETA, 1.0g DIBHT, 0.28g dodecanethiol, 0.39g Na~P20~10H20,lOO g water. Based on butadiene charge. WAQE WAQE 20 8.0 20 20 20 20 20 20 20 time (hr) 12.0 4.0 8.0 4.0 4.0 8.0 0.0 12.0 0.0 4.0 Tween 80 Tween 80 Tween 80 83-44b 83-32 83-39 83-47b 83-37 97-7 83-48 97-16 83-45 97-12 97-14 F-68 F-68 F-68 F-68 F-68 F-68 g NaSS Emulsifier Experiment* TABLE I11 Effect of SSS Concentration in the Reaction Charge on the Copolymer Product Solubility (%) Reaction Conversionb ?l 3 B 8 * 3 0 m 2z B 8 W rp W rp 0.00 0.72 0.72 0.72 0.72 1.45 0.72 1.45 83-34' 83-32' 83-31ad 83-37' 97-7c 97-9= 83-48e 97-3e 87 67 68 93 95 87 >lo0 >100 5 75 58 59 29 67 15 36 Toluene 33 78 100 100 92 100 38 55 Solubility (%) Mixed solvent 67 22 0 0 8 0 62 45 Gel ?red 1.7 1.6 1.7 2.1 2.3 1.4 0.79 0.59 %S 0.29 0.44 0.46 0.61 0.57 0.64 1.44 1.06 a Reaction formulation: 38.8 g butadiene, variable SSS, 4.6 g emulsifier, 1.0 g TETA, 1.0 g DIBHT, variable dodecanethiol, 0.39 g NarP207.10H20,lOO g water. Based on butadiene charge. 4.0 g SSS in charge. Double the reaction formulation of 83-32. 8.0 g SSS in charge. (%) Thiolb Emulsifier Tween 80 Tween 80 Tween 80 Pluronic F-68 Pluronic F-68 Pluronic F-68 Pluronic F-68 Pluronic F-68 Experiments Conversionb (% 6 20 hr) TABLE IV Effect of Chain Transfer Agent on the Copolymer Product rn 2 cd ! c3 z G0 E E 3 -4 rn WEISS, LUNDBERG, AND WERNER 3436 I I I I 1.4 .o 1.2 .6 1 .o .2 0.8 L S ‘red 0.6 .8 0.4 .4 0.2 0 0 I I 20 40 I I 60 80 100 (X) Fig. 2. Copolymer composition and molecular weight versus conversion. CONVERSION Conversion The composition, molecular weight, and solubility behavior of the butadiene-SSS copolymers prepared in this investigation were strongly dependent on the extent of the reaction demonstrated in Figure 2 and Table V. The SSS content of the copolymer decreased and the molecular weight increased with increasing conversion. Some question exists, however, of the validity of the higher sulfonate concentrations for the samples a t the three lowest conversions TABLE V Characteristicsof Butadiene-NaSS Copolymers as a Function of Conversion (Experiment 83-19) Solubility (%) Mixed Xylene solventa Conversion Sample (%) %S q,,d 83-19-4 83-19-5 83-19-6 83-19-3 83-19-1 83-19-2 4 13 29 64 67 1.34 0.95 0.90 0.70 0.56 0.46 0.39 0.36 0.37 0.48 1.8 1.9 100 100 100 100 56 44 98 99 99 99 100 95 Ionic fractionb Gel (%) 0 0 0 0 0 0 5 0 0 0 44 51 * Reaction formulation: 29.0 g butadiene, 3.0 g SSS, 2.3 g Tween 80,0.5g TETA, 0.5 g DIBHT, 0.29 g Na4PzOylOH20,50g water. 95/5 Toluene/methanol. % Ionic fraction = (mixed solvent solubility) (xylene solubility). - SYNTHESIS OF SULFONATED POLYMERS 3437 (83-19-4,5,and 6). These polymers were extremely tacky greases, and it is not certain whether all of the unreacted SSS monomer was removed during the workup of the polymer. The solubility data in Table V indicate that the ionic character of the copolymer increased at the higher conversions, even though the measured sulfonate content decreased. The solubilities in mixed solvent of the copolymer products prepared with the three nonionic surfactants and three concentrations of chain transfer agent are plotted against conversion in Figure 3. Although other variables such as the reaction temperature, SSS charge, and latex stability may affect the copolymer products, it appears that insoluble polymer, that is,'gel, was formed preferentially a t conversions greater than 60%. This suggests that crosslinking reactions become important a t higher conversions, a result that is not uncommon in the polymerization of diene monomers. Compositional Heterogeneities Fractionations of the butadiene-SSS copolymers with the different solvents used in this study suggest that these materials were heterogeneous with regard to composition. The sulfur analyses (SSS content) and reduced viscosities (molecular weight) for various fractionated polymers are given in Tables VI and VII. The data in Table VI indicate that the nonionic toluene-soluble materials were, in general, lower in SSS concentration and lower in molecular weight than the ionic, toluene-insoluble-mixed-solvent solution fractions. These results Soluble Fraction KEY (9) SYMBOL 40 - EMULSIFIER TWEEN 80 0 0 F 68 A WAQE 01 0 4 0 ' I [CTA]/[C4H61 SYMBOL 2o - I 0 0 Filled Empty 0.005 HalfFilled 0.007 I 20 I I I J 40 60 80 100 CONVERSION ( X ) Fig. 3. Copolymer solubility versus conversion. WEISS, LUNDBERG, AND WERNER 3438 TABLE VI Characteristicsof Toluene-Soluble and -InsolubleFractions of Butadiene-SSS Copolymers ~~ Experiment Sulfur analysis (% S) Unfractionated Toluene- Toluenepolymer soluble insoluble 83-37 83-39 83-45 83-48 97-1 97-3 97-5 97-7 97-26-2 a 0.61 0.99 0.80 1.44 1.31 1.06 0.61 0.57 0.94 0.49 0.66 0.32 0.56 0.93 0.72 0.41 0.47 0.56 0.64 1.09 1.03 1.71 2.20 1.44 0.71 0.64 1.23 Reduced viscosity (dl/g)a Toluene- Toluene- Combined soluble insoluble sample 0.98 0.48 - 2.5 1.1 1.5 1.2 - 0.49 1.2 2.1 0.77 1.o 0.79 0.65 0.59 1.31 2.3 1.1 Measured in a mixed solvent of toluene and methanol (95/5) at 25OC. TABLE VII Composition of Mixed-Solvent-Solubleand -InsolubleFractions of Butadiene-SSS Copolymers Experiment 83-39 83-45 83-48 97-3 Sulfur analysis (a S) Mixed solvent soluble 0.94 0.55 0.65 0.67 Gel 1.21 1.39 1.98 1.44 are consistent with the observation that the toluene-soluble materials were usually fairly tacky and had little tensile strength. On the other hand, the toluene-insoluble-mixed-solvent-soluble fractions were nontacky, elastic solids that exhibited superior mechanical characteristics. It was pointed out earlier in this article that the distinction between covalent and ionic crosslinking in ionomers is not always obvious. In this regard the data in Table VII are especially noteworthy. These data show that the insoluble, or gel, material contained a higher concentration of the ionic moiety SSS than the soluble materials, which suggests that the insolubility of these polymers may result from strong ionic associations rather than covalent crosslinking, although this conclusion has not been confirmed. CONCLU$IONS AND FUTURE WORK The overall objective of this study was to explore the viability of copolymerization as a route to sulfonate ionomers. The copolymerization of butadiene with sodium styrene sulfonate has been studied and the copolymer products have been characterized. The effects of the various reaction variables on the copolymer products have been described, and under suitable conditions copolymers that exhibit behavior typical of previously evaluated ionomers can be prepared. Additional work is needed, however, to characterize further the mechanism of this particular copolymerization and the copolymer products. SYNTHESIS OF SULFONATED POLYMERS 3439 References 1. A. Eisenberg and M. King, Ion-ContainingPolymers, Academic, New York, 1977. 2. H. S. Makowski and R. D. Lundberg, Polym. Prepr., 19(2), 304 (1978). 3. L. Holliday, Ed., Ionic Polymers, Applied Science, London, 1975. 4. H. S. Makowski, R. D. Lundberg, L. Westerman, and J. Bock, Polym. Prepr., 19(2), 292 (1978). 5. D. Rahrig and W. J. MacKnight, Polym. Prepr., 19(2),314 (1978). 6. W. J. MacKnight and T. R. Earnest, Jr., J. Polym. Sci., in press. 7. D. A. Kangas, in Functional Monomers, Vol. 1,R. H. Yocum and E. B. Nyquist, Eds. 1973, Chapter 4. 8. C. S. Marvel, V. C. Menikheim, H. K. Inskip, W. K. Taft, and B. G. Labbe, J.Polym. Sci., 10, 39 (1955). 9. Japanese Pat. 72/51954 (1972). 10. B. Oster and R. W. Lenz, Research Report to Exxon Research and Engineering, December 1975. 11. R. D. Lundberg and H. S. Makowski, Polym. Prepr., 19(2),287 (1978). Received March, 28,1980 Accepted May 30,1980
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