polymers Article Tailoring Copolymer Properties by Gradual Changes in the Distribution of the Chains Composition Using Semicontinuous Emulsion Polymerization Carlos Federico Jasso-Gastinel 1, *, Alvaro H. Arnez-Prado 1 , Francisco José Aranda-García 1 , Luis Octavio Sahagún-Aguilar 1 , Fernando A. López-Dellamary Toral 2 , María Elena Hernández-Hernández 1 and Luis Javier González-Ortiz 2 1 2 * Chemical Engineering Department, Universidad de Guadalajara, 44100 Guadalajara, Mexico; [email protected] (A.H.A.-P.); [email protected] (F.J.A.-G.); [email protected] (L.O.S.-A.); [email protected] (M.E.H.-H.) Chemistry Department, Universidad de Guadalajara, 44100 Guadalajara, Mexico; [email protected] (F.A.L.-D.T.); [email protected] (L.J.G.-O.) Correspondence: [email protected] Academic Editor: Graeme Moad Received: 21 December 2016; Accepted: 13 February 2017; Published: 22 February 2017 Abstract: To design the properties of a copolymer using free radical polymerization, a semicontinuous process can be applied to vary the instantaneous copolymer composition along the conversion searching for a specific composition spectrum of copolymer chains, which can be termed as weight composition distribution (WCD) of copolymer chains. Here, the styrene-n-butyl acrylate (S/BA) system was polymerized by means of a semicontinuous emulsion process, varying the composition of the comonomer feed to obtain forced composition copolymers (FCCs). Five different feeding profiles were used, searching for a scheme to obtain chains rich in S (looking for considerable modulus), and chains rich in BA (looking for large deformation) as a technique to achieve synergy in copolymer properties; the mechanostatic and dynamic characterization discloses the correspondence between WCD and the bulk properties. 1 H-nuclear magnetic resonance (1 H-NMR) analysis enabled the determination of the cumulative copolymer composition characterization, required to estimate the WCD. The static test (stress-strain) and dynamic mechanical analysis (DMA) were performed following normed procedures. This is the first report that shows very diverse mechanostatic performances of copolymers obtained using the same chemical system and global comonomer composition, forming a comprehensive failure envelope, even though the tests were carried out at the same temperature and cross head speed. The principles for synergic performance can be applied to controlled radical copolymerization, designing the composition variation in individual molecules along the conversion. Keywords: copolymer; free radical; mechanical properties; semicontinuous polymerization; composition distribution; gradual composition changes; synergic performance 1. Introduction Since the twentieth century, different blending methods, types of reactions, and polymerization processes have been used to prepare two component polymers, attempting to combine or optimize properties, expand applications, or simply optimize the cost/properties relationship [1–3]. It has been demonstrated that the contribution of each polymeric component is improved if phase separation occurs at the microscopic level, which implies that chemical blending offers better component interaction than physical blending [4]. Additionally, the mechanical superiority of polymer blends Polymers 2017, 9, 72; doi:10.3390/polym9020072 www.mdpi.com/journal/polymers Polymers 2017, 9, 72 2 of 11 containing a gradient in composition over materials with uniform composition in the polymer bulk (e.g., gradient interpenetrating polymer networks (gIPNs) versus regular IPNs obtained by a three step method using bulk polymerization) has been shown [5–7]. Such superiority has been attributed to the synergic contribution of polymeric region(s) rich in component A as well as of region(s) rich in component B, in the spatial structure of the bulk polymer, which leads to the optimization of properties [6]. Moreover, using the suspension process, forming gradients by comers/monomer diffusion in polymer beads followed by an in situ polymerization, better control in transport properties [8,9], or ionic exchange optimization [10,11] has been achieved in polymer blends. Nevertheless, for materials obtained by conventional or traditional free radical polymerization (FRP), if sequential homopolymerizations of A and B components are used in emulsion, a two-phase core-shell type polymer is usually obtained, where phase separation generates a weak interaction between the components, inhibiting the optimization of properties. However, by appropriate comonomer mixing taking advantage of their common difference in reactivities [12], gradients in composition have been formed since a long time ago to produce for example a gradient in properties like refraction-index in copolymers [13]. Basically, gradients in polymers may be formed in one or more constituents of a polymeric material, carrying out variations in space, structure, composition, or synthesis method [14–17]. With that perspective, taking into consideration that covalent bonding offers the strongest component interaction and that gradients in composition help for the synergic contribution of the attributes of each component, the attainment of convenient gradual changes in the composition spectrum of copolymer chains (weight composition distribution of chains; WCD) could improve the mechanical properties. One way to search for these characteristics using free radical copolymerization (FRC) is to prepare copolymers by means of a semicontinuous process varying the feed comonomer composition along the reaction. That is, in principle forcing the reaction, copolymer chains rich in A, as well as chains rich in B can be formed, regardless of the relative reactivities (for not extremely distant values). Additionally, with a gradual variation in feeding composition, the formation of chains with intermediate compositions of monomers A and B can also be attained; such chains may serve as compatibilizers to reduce the tendency to separate the polymer bulk into two phases. With that aim, using the styrene-2-ethylhexyl acrylate system with a seeded multistage semicontinuous emulsion process, promising results were reported years ago using linear feeding profiles for the comonomers with variations in global composition [18]; besides, seed type or particle size may also be varied [19]. If the cumulative composition of the copolymer chains is followed along the reaction and used to estimate the WCD of the copolymer bulk, the copolymer properties can be correlated to that composition spectrum. With this aim, the styrene/n-butyl acrylate (S/BA) system with styrene seed was polymerized in emulsion, considering several feeding profiles for the 70/30 w/w composition. For the copolymers obtained, significant changes in the toughening effect caused by the BA contribution were observed, while their Young’s modulus was sustained to a certain extent at room temperature. Those changes in mechanical behavior corresponded to variations in the copolymer composition spectrum [20]. Based on those results, to demonstrate the full correspondence between the composition spectrum of the copolymer chains and the mechanical properties (dynamic and static) of a copolymer system, in this study several feeding profiles using the 50/50 w/w S/BA as chemical system and a semicontinuous emulsion process were considered and the correspondent WCDs are estimated. The S/BA monomer pair is a system of interest for the combination of rigidity-elasticity properties with distant glass transition temperatures (–55 ◦ C for BA and 100 ◦ C for S correspond to the homopolymers), and shows moderate phase segregation [21]. Their relative reactivities are 0.19 for BA and 0.72 for S [22]. For the reactions, starting with a polystyrene (PS) seed, predetermined feeding stages are used with linear, parabolic, or linear V type (e.g., linear descendant-ascendant) profiles to change the instantaneous S/BA comonomer composition and orientate, since at the beginning of the reaction the composition changes in the new copolymer chains. With the feeding schemes used, the formation of chains rich in S units (looking for a high modulus) and chains rich in BA units (for high deformation Polymers 2017, 9, 72 3 of 11 capacity) is intended. In the end, this approach may be used as a method to tailor the properties by means of useful gradual changes in the WCD of the copolymer chains. To be used as references for mechanical properties, an equivalent statistical copolymer (SC) and a core-shell type polymer in two stages (T-S) were also prepared and tested. 2. Experimental Section Materials Styrene and n-butyl acrylate monomers (both from Sigma Aldrich, St, Louis, MO, USA, purity >99%) were disinhibited with ionic exchange resins; methyl ester hydroquinone resin was used for BA, and 4-tert-butylcathechol for S. As surfactant, sodium dodecylsulfate (SDS; Aldrich, St, Louis, MO, USA, purity >98%) was used as acquired. Potassium persulfate was used as initiator (KPS; Aldrich, purity >98%). Sodium bicarbonate (Arm and Hammer, Ewing, NJ, USA) was used to Polymers 2017, 9, 72 the reaction. Distilled water was used for every polymerization 3 of 11 buffer pH changes during reaction. In all polymerizations, nitrogen gas was used to purge the reaction system. Twenty wt % of solid mechanical properties, an equivalent statistical copolymer (SC) and a core-shell type polymer in two (T-S) were also prepared and tested.at the end of every reaction. The reactions were carried polymer (PS, T-Sstages or copolymers) was obtained out at 70 ◦ C in a2. Experimental 4 L glass reactor, stirring the system at 400 rpm; reaction times >12 h were used Section Materials to maximize monomer(s) conversion (followed by from gravimetry). SC MO, synthesis was carried out Styrene and n-butyl acrylate monomers (both Sigma Aldrich,The St, Louis, USA, purity >99%) were disinhibited with ionic exchange resins; methyl ester hydroquinone resin was used by adding quickly to the reactor the required amount of monomers (S/BA, 50/50forw/w) at room BA, and 4-tert-butylcathechol for S. As surfactant, sodium dodecylsulfate (SDS; Aldrich, St, Louis, temperature while stirring. Before the addition of the required amount of initiator, the whole system MO, USA, purity >98%) was used as acquired. Potassium persulfate was used as initiator (KPS; purity >98%).reaction. Sodium bicarbonate andpolymeric Hammer, Ewing, NJ, USA) was used to buffer was heated up toAldrich, start the batch For the(Arm other materials, a PS seed was obtained first pH changes during the reaction. Distilled water was used for every polymerization reaction. In all by batch emulsion polymerization. The T-S polymer was obtained by adding to the reactor the required polymerizations, nitrogen gas was used to purge the reaction system. Twenty wt % of solid polymer amount of PS seed the second stage at the of reactions BA monomer (BA/PS, (PS,and T-S orfor copolymers) was obtained therequired end of everyamount reaction. The were carried out at 50/50 w/w) 70 °C a 4 Laglass reactor, stirring the system at 400 rpm; reaction times >12 h were used up to and a similar was quickly added toinsuch reactor while stirring; then, the whole system was heated maximize monomer(s) conversion (followed by gravimetry). The SC synthesis was carried out by procedure to theadding one quickly followed the the SCrequired synthesis was carried out. forced to thefor reactor amount of monomers (S/BA, The 50/50 five w/w) at room composition temperature stirring. by Before the addition of the required amount of initiator, the whole system copolymers (FCCs) werewhile obtained means of seeded semicontinuous emulsion processes; for the was heated up to start the batch reaction. For the other polymeric materials, a PS seed was obtained FCCs the global first styrene content was also 50 wt %. At the start of each copolymerization reaction, the by batch emulsion polymerization. The T-S polymer was obtained by adding to the reactor the required amount of PSlatex seed and for the second required amount of BA monomer (BA/PS,water required reactor was charged with a seed containing 50stage g ofthePS and the amount of distilled 50/50 w/w) was quickly added to such a reactor while stirring; then, the whole system was heated up to complete 1600 g of total load. Then, 10 sequential “comonomer feeding stages” of 12 min each and a similar procedure to the one followed for the SC synthesis was carried out. The five forced one were implemented for(FCCs) the Vwere type feeding profile where 20 stages of 6 min were used). composition(except copolymers obtained by means of seeded semicontinuous emulsion the FCCs the global styrene content was also 5045wtg %. At the for start the of each At the beginningprocesses; of eachforstage, an aqueous solution containing (except reaction of the V copolymerization reaction, the reactor was charged with a seed latex containing 50 g of PS and the type feeding profile, where 22.5 g of water were used) of distilled water, and the required amounts amount of distilled water required to complete 1600 g of total load. Then, 10 sequential “comonomer feeding stages” of 12 min each one were implemented (except for the V type feeding profile where of KPS, SDS, and NaHCO3 were added as a batch to the reaction system. In every stage, the amount 20 stages of 6 min were used). At the beginning of each stage, an aqueous solution containing 45 g added of each salt wasforthe corresponding to 2% of where the total ofwere theused) comonomers (except the one reaction of the V type feeding profile, 22.5 gmass of water of distilled to be added water, and the required amounts of KPS, SDS, and NaHCO 3 were added as a batch to the reaction to the reactor in that stage. The feeding flow was modified at the start of each stage, and pumped system. In every stage, the amount added of each salt was the one corresponding to 2% of the total (Masterflex L/Smass 7528-10) at constant flow rate during the stage. Five feeding profile combinations of the comonomers to be added in that stage. The feeding flow was modified at the start of each for the S and BAstage, comonomers implemented (M1 –M ), by means linear (L1 Five or L2 ), parabolic and pumped towere the reactor (Masterflex L/S 7528-10) at5constant flow rate of during the stage. feeding profile combinations for the S and BA comonomers were implemented (M 1–M5), by means of (Pa), linear ascendant-linear descendant (A), and linear descendant-linear ascendant (D) trajectories. linear (L1 or L2), parabolic (Pa), linear ascendant-linear descendant (A), and linear descendant-linear Such individual ascendant flow profiles are shown in Figure 1a–e with theinfollowing schemes: L2 S/L1 BA (M1 ); (D) trajectories. Such individual flow profiles are shown Figure 1a–e with the following L2S/L1BA(M (M1););PaS/L 1BA (M 2); L1(M S/PaBA (M 3); L1S/L1BA(M (M4););DS/ABA (M 5); in all cases the PaS/L1 BA (M2 );schemes: L1 S/PaBA L S/L BA ); DS/ABA in all cases the feeding time was 3 1 1 4 5 feeding time was predetermined as 2 h. predetermined as 2 h. 6 5 Comonomer Flow (g/min) Comonomer Flow (g/min) 6 L2S L1BA 4 3 2 1 0 5 PaS L1BA 4 3 2 1 0 0 20 40 60 80 100 120 0 20 40 60 Time (min) Time (min) (a) (b) Figure 1. Cont. 80 100 120 Polymers 2017, 9, 72 4 of 11 Polymers 2017, 9, 72 4 of 11 6 8 L 1S PaBA Comonomer Flow (g/min) Comonomer Flow (g/min) 10 6 4 2 0 0 20 40 60 80 100 L1S L1BA 5 4 3 2 1 0 120 0 20 40 Time (min) 60 80 100 120 Time (min) (c) (d) Comonomer Flow (g/min) 6 DS ABA 5 4 3 2 1 0 0 20 40 60 80 100 120 Time (min) (e) Figure 1. Comonomers flow as a function of reaction time, for S/BA FCCs synthesis: (a) M1 (L2S/L1BA); (b) Mas 2 (PaS/L 1BA); (c) M 3 (L 1S/PaBA); (d) M4 (Lfor 1S/L1S/BA BA); andFCCs (e) M5 (DS/ABA). Figure 1. Comonomers flow a function of reaction time, synthesis: (a) M1 (L2 S/L1 BA); (b) M2 (PaS/L1 BA); (c) M3 (L1 S/PaBA); (d) M4 (L1 S/L1 BA); and (e) M5 (DS/ABA). For the characterization of each FCC material, seven samples were extracted at predetermined reaction times, to be measured by 1H-NMR (Varian Gemini 2000, Agilent Technologies, Palo Alto, CA, USA) their respective global styrene percentage ( values) and, by gravimetry their For the characterization of each FCC material, seven samples were extracted at predetermined respective global conversion values ( values). For the calculations to build up the WCD, the reaction times, toconversion be measured by 1 H-NMR (Varian Gemini 2000, Agilent interval (from 0% up to the final experimental conversion value) Technologies, was discretized in Palo Alto, CA, subintervals of 0.1% in width. It was considered that all the chains produced inside of each USA) their respective global styrene percentage (SPexp values) and, by gravimetry their respective conversion subinterval i (characterized by its respective value) have the same value, which global conversion the calculations to build upabove the WCD, the conversion expa values). was values estimated(X with third order For polynomial obtained by fitting the seven mentioned experimental values; for experimental this, the least squares method was used. The total mass of monomer j in (S or interval (from 0% up to the final conversion value) was discretized subintervals of BA) polymerized up to subinterval i ( ) can be calculated with the following equations: 0.1% in width. It was=considered that= all the chains produced inside of each conversion subinterval 100 − , or, being the total amount of monomer (S plus i (characterizedBA) byincluded its respective Xi (450 value) have theofsame SPji polymerized value, which was estimated with a in the reaction g). Thus, the mass monomer in the subinterval i ∆ can beobtained estimated asby follows: ∆ = − above the mass percentage of . Therefore, third order polynomial fitting the seven mentioned experimental values; for S in the chains formed in the subinterval i % can be obtained with the following equation: this, the least squares method was .used. The total mass of monomer j (S or BA) polymerized up % = ∆ ∆ +∆ The respective masses of polymer produced with % values within j composition intervalswith (e.g., 0%–5% of S, 5%–10% equations: of S and so on) were to subinterval ithe (mpre-established ) can be calculated the following mSupsuitably to i = Xi MT SPi or, up to i summed up and, with such values, the histograms showing the WCD profiles for the copolymer mBA − CPi ),inM the total amount of monomer (Swere plus BA) included in the (100contained T being each FCC material at the end of the reaction (Figure 2a,b) constructed up to i = Xi MTchains j [19,20]. reaction (450 g). Thus, the mass of monomer j polymerized in the subinterval i (∆mi ) can be estimated All latexes were dried by evaporation at room temperature; the collected high molecular weight j j j as the ones reported before [18–20]), were used to prepare samples by compression as follows: ∆mi polymers = (mup(such to i +1 − mup to i ). Therefore, the mass percentage of S in the chains formed in molding (Schwabenthan polystat 200T) to carry out all mechanical tests. Stress-strain measurements the subinterval i (%Si ) can be obtained with the following equation: %Si = ∆mSi / ∆mSi + ∆mBA . i The respective masses of polymer produced with %Si values within the pre-established composition intervals (e.g., 0%–5% of S, 5%–10% of S and so on) were suitably summed up and, with such values, the histograms showing the WCD profiles for the copolymer chains contained in each FCC material at the end of the reaction (Figure 2a,b) were constructed [19,20]. All latexes were dried by evaporation at room temperature; the collected high molecular weight polymers (such as the ones reported before [18–20]), were used to prepare samples by compression molding (Schwabenthan polystat 200T) to carry out all mechanical tests. Stress-strain measurements were performed at 25 ◦ C following the procedure of the American Society for Testing Materials (ASTM D638, samples Type IV, crosshead speed: 0.0083 cm/s; Universal testing machine SFM10). A dynamic mechanical analysis (DMA) was carried out to measure storage and loss moduli as a function of temperature (ASTM D-5023, three point bending clamp, 1 Hz, heating rate: 1 ◦ C/min TA Instruments Q800, Waters Corporation, New Castle, DE, USA). 0.30 Weight fraction of copolymer chains Weight fraction of copolymer chains were performed at 25 °C following the procedure of the American Society for Testing Materials (ASTM D638, samples Type IV, crosshead speed: 0.0083 cm/s; Universal testing machine SFM10). A dynamic mechanical analysis (DMA) was carried out to measure storage and loss moduli as a function of temperature (ASTM D-5023, three point bending clamp, 1 Hz, heating rate: 1 °C/min TA Instruments Q800, Waters Corporation, New Castle, DE, USA). Polymers 2017, 9, 72 5 of 11 M1 (L2S/L1BA) M2 (PaS/L1BA) 0.25 0.20 0.15 0.10 0.05 0.00 0 20 40 60 80 Styrene weight percentage in copolymer chains (a) 100 0.30 M3 (L1S/PaBA) M4 (L1S/L1BA) M5 (DS/ABA) 0.25 0.20 0.15 0.10 0.05 0.00 0 20 40 60 80 100 Styrene weight percentage in copolymer chains (b) Figure 2. Weight fraction of copolymer chains of FCCs as a function of styrene weight percentage in Figure 2. Weight fraction of copolymer chains of FCCs as a function of styrene weight percentage the copolymer chains, estimated for: (a) M1, and M2, materials and (b) M3, M4, and M5 materials. For in the copolymer chains, estimated for: (a) M1 , and M2 , materials and (b) M3 , M4, and M5 materials. codes, see Figure 1. For codes, see Figure 1. 3. Results and Discussion 3. Results and Discussion The chosen feeding profiles (Figure 1a–e) allow the diversification of composition histograms Therepresent chosen feeding profiles 1a–e) allow the of composition histograms that that the WCDs of (Figure the FCCs presented in diversification Figure 2a,b. The feed trajectories allow the represent the WCDs of the FCCs presented in Figure 2a,b. The feed trajectories allow the formation formation of chains that are rich in styrene or butyl acrylate at different moments depending on theof chains that are rich or butyl acrylatethe at continuous different moments depending the flow profile flow profile and in thestyrene monomer reactivities; change in monomeron composition allowsand a the biased monomer reactivities; the continuous change in monomer composition allows a biased change change in the instantaneous copolymer composition. The composition profiles shown in Figure 2a,b definecopolymer the mechanical properties that are presented in Figures 3–5. Even though the in the instantaneous composition. The composition profiles shown in Figure 2a,b define copolymer composition determines the mechanical performance that may vary from highly elastic the mechanical properties that are presented in Figures 3–5. Even though the copolymer composition (almost pure poly(butyl acrylate) (PBA),that to highly rigidfrom behavior (almost pure PS), the deformation determines the mechanical performance may vary highly elastic (almost pure poly(butyl capacity and moduli are affected by both components depending on the chains buildup along the acrylate) (PBA), to highly rigid behavior (almost pure PS), the deformation capacity and moduli composition spectrum. The correlation between the WCD of a copolymer and its correspondent are affected by both components depending on the chains buildup along the composition spectrum. canWCD be disclosed, quantifying 2a,b the weight fraction accumulation Themechanical correlationproperties between the of a copolymer and in itsFigure correspondent mechanical properties can be or wt % of the copolymer chains within specific composition ranges (e.g., 0–60 wt %, which can be disclosed, quantifying in Figure 2a,b the weight fraction accumulation or wt % of the copolymer chains designated as styrene composition interval or simply SI 0–60). within specific composition ranges (e.g., 0–60 wt %, which can be designated as styrene composition For the general FCC behavior, even though the chains that are close to an extreme of the ordinate interval or simply SI 0–60). axis will have significant influence on the property related to the pure homopolymer (i.e., at 0 wt % the For the general FCC behavior, even though the chains that are close to an extreme of the ordinate behavior stands for PBA and at 100 wt % to PS), the synergic performance also requires the axis will have significant influence on the property related to the pure homopolymer (i.e., at 0 wt % the considerable presence of chains that contain both components (as a fundamental difference to T-S behavior standsInfor PBA and at 100 wtat % to thehistograms synergic performance requires the considerable materials). that sense, looking thePS), FCC as a wholealso in Figure 2a,b, the highest presence of chains that contain both components (as a fundamental difference to T-S materials). In4 that mechanical moduli can be expected for M1 and M2, but higher deformations can be expected for M or sense, looking at the FCC histograms as a whole in Figure 2a,b, the highest mechanical moduli can be M5. expectedFor forthe M1FCCs and M deformations canseen be expected forof Mstress-strain 2 , but higher 4 or M5 . presented in Figure 3, it can be that the set curves at 25 °C For the FCCs presented in Figure 3, it can be seen that the set of stress-strain curvesenvelope at 25 ◦ C encompass an extensive range of mechanical performance, forming in fact a wide failure encompass range of mechanical performance, formingspeed) in fact[23], a wide failure envelope (althoughanit extensive was obtained at the same temperature and cross-head which only depends (although was obtained at the same temperature and cross-head which only depends on on the itWCD of such materials, because they possess the samespeed) global[23], composition. The Young’s (E) and deformation ranksthe forsame the global FCCs can be seen in Table 1 and their the modulus WCD of such materials, becausecapacity they possess composition. The Young’s modulus correlations with capacity the WCDranks can be by be observing Table12.and In their principle, the higher (E) and deformation forestablished the FCCs can seen in Table correlations withthe the modulus, lower theby deformation; is, 2. basically the FCCs position values inthe E WCD can be the established observing that Table In principle, theoccupy higheropposite the modulus, the lower and deformation However, looking at the curves position of Figurevalues 3, it caninbeEinferred that the design deformation; that is,ranks. basically the FCCs occupy opposite and deformation ranks. However, looking at the curves of Figure 3, it can be inferred that the design of the WCDs may be used to obtain a good combination of E and deformation, searching for considerable rigidity and toughness. Polymers 2017, 9, 72 6 of 11 of the WCDs may be used to obtain a good combination of E and deformation, searching for 6 of 11 and toughness. Polymers 2017, 9, 72rigidity considerable 8 M1 M2 M3 M4 M5 T-S SC Strees 6 4 2 2600% 0 0 10 20 30 40 50 60 Strain (%) Figure 3. 3. Stress-strain behavior of of FCCs (M(M two polymer (T-S) and statistical copolymer Figure Stress-strain behavior FCCs 1–M twostage stage polymer (T-S) and statistical copolymer 1 –M 5 ),5), ◦ C (crosshead speed: 0.5 cm/min). For FCCs codes, see Figure 1. (SC) at 25 (SC) at 25 °C (crosshead speed: 0.5 cm/min). For FCCs codes, see Figure 1. Table 1. Young’s modulus andand ultimate properties of FCCs (M1 –M ), as as T-S SC materials at 5),well as well as and T-S and SC materials Table 1. Young’s modulus ultimate properties of FCCs (M15–M 25at◦ C25and crosshead speed of 0.5ofcm/min. For For codes, see Figures 1 and 2. 2. °C and crosshead speed 0.5 cm/min. codes, see Figures 1 and Property Property Young (MPa) YoungModulus Modulus (MPa) Ultimate (MPa) Ultimate Stress Stress (MPa) Ultimate Strain Strain (%) Ultimate (%) Toughness (MPa) Toughness (MPa) 1 MM M2M2 M3 M3 M4 M4 M5 M5 T-S T-S SC SC 1 440 ± 20 200 ± 30 120 ± 30 90 ± 20 0.35 ± 0.10 30 ± 30 440 ± 20 200 ± 30 120 ± 30 90 ± 20 0.35 ± 0.10 30 ± 30 20 ± 420 ± 4 ± 0.4 2.2 ± 2.20.3± 0.3 2.8 ± 2.80.4± 0.40.120.12 ± 0.070.9 ±0.9 1.0 ± 0.1 7.47.4 ±± 0.80.8 3.03.0 ± 0.4 ± 0.07 0.1 ± 0.1 1.0 ± 0.1 ± 300± 300 13.9 ± 1.9 ± 1.9 35.5 ±35.5 1.1 ± 1.1 2.22.2 ±± 0.20.2 15.6 ± 2.3 15.6 ± 2.3 6.1 ± 6.11.8± 1.8 54 ±5415± 1526002600 13.9 11.0 ± 0.6 48.5 ± 0.9 11.7 ± 1.0 150 ± 2 630 ± 5 11.7 ± 0.7 31.5 ± 2.4 11.0 ± 0.6 48.5 ± 0.9 11.7 ± 1.0 150 ± 2 630 ± 5 11.7 ± 0.7 31.5 ± 2.4 Table 2. 2. Weight fraction of of copolymer chains of of FCC samples whose composition is is within a specific Table Weight fraction copolymer chains FCC samples whose composition within a specific interval. For codes, see Figure 1. interval. For codes, see Figure 1. M55 M1 M2 M2 M3M3 MM 44 0.2090.2070.207 0.112 0.112 0.134 0.134 0.001 0.001 0.0620.0630.063 0.177 0.177 0.035 0.035 0.005 0.005 0.017 0.0630.0780.078 0.086 0.086 0.040 0.040 0.017 0.081 0.075 0.050 0.153 0.064 0.081 0.075 0.050 0.153 0.091 0.064 0.073 0.533 0.0710.0940.091 0.070 0.064 0.349 0.073 0.533 0.103 0.0700.0940.094 0.065 0.070 0.137 0.349 0.103 0.044 0.033 0.0790.0890.094 0.072 0.065 0.056 0.137 0.044 0.000 0.0900.0810.089 0.081 0.072 0.020 0.056 0.033 0.122 0.197 0.105 0.110 0.1010.2700.081 0.289 0.081 0.169 0.020 0.000 0.006 0.1910.3480.122 0.375 0.197 0.209 0.105 0.110 0.023 0.812 0.2710.6140.270 0.585 0.289 0.682 0.169 0.006 0.789 0.3340.2670.348 0.209 0.375 0.473 0.209 0.023 0.186 0.134 0.422 0.636 0.539 0.614 0.585 0.682 0.812 0.183 0.137 0.193 0.077 0.2050.3860.267 0.415 0.209 0.318 0.473 0.789 0.188 0.1410.2920.186 0.350 0.134 0.182 0.422 0.636 0.143 0.110 0.1690.2030.183 0.278 0.137 0.125 0.193 0.077 1.000 0.4611.0000.386 1.000 0.415 1.000 0.318 0.188 70–100 0.382 0.292 0.350 0.182 0.143 80–100 show the highest 0.292and0.203 0.125 0.110 whose values In Figure 3, M1 and M5 clearly lowest0.278 modulus respectively 0–100 1.000 1.000 1.000 1.000 1.000 can be seen in Table 1. In Table 2, it can be noticed that they present significant differences in favor of M Styrene % inChains Cop. ChainsM1 Styrene wt %wt in Cop. 0–10 0–10 10–2010–20 20–3020–30 30–40 30–40 40–50 50–6040–50 60–7050–60 70–8060–70 80–9070–80 90–100 80–90 0–20 90–100 0–30 0–60 0–20 30–60 0–30 40–60 0–60 60–80 30–60 60–100 70–10040–60 80–10060–80 0–10060–100 0.209 0.062 0.063 0.064 0.071 0.070 0.079 0.090 0.101 0.191 0.271 0.334 0.539 0.205 0.141 0.169 0.461 0.382 0.292 1.000 1 for the wt % of copolymer chains that are rich in S (SI 70 or 80–100), and even since SI 60–100, because In Figure 3, M1 and M5 clearly show the highest and lowest modulus respectively whose values the wt % content of copolymer chains for that range are 46.1 for M1 versus 18.8 for M5 . In contrast, can be seen in Table 1. In Table 2, it can be noticed that they present significant differences in favor of for the composition ranges below 60 wt % S, the big differences are in favor of M5 especially for the SI 40–50 region (53.3 wt % for M5 versus 7.1 wt % of chains for M1 ), or the accumulated for SI 0–60 M1 for the wt % of copolymer chains that are rich in S (SI 70 or 80–100), and even since SI 60–100, because the wt % content of copolymer chains for that range are 46.1 for M1 versus 18.8 for M5. In contrast, for the composition ranges below 60 wt % S, the big differences are in favor of M5 especially for the2017, SI 40–50 SI Polymers 9, 72 region (53.3 wt % for M5 versus 7.1 wt % of chains for M1), or the accumulated 7for of 11 0–60 (53.9 for M1 versus 81.2 for M5), denoting the high capacity of M5 for deformation. Such extreme stress-strain behaviors may be used as a basis to look at the general trends for the FCCs. (53.9 for M1 versus 81.2 for M5 ), denoting the high capacity of M5 for deformation. Such extreme Comparing the differences for the M2–M4 materials regarding Young modulus, in Figure 3 the stress-strain behaviors may be used as a basis to look at the general trends for the FCCs. curves almost overlap at the origin and that proximity is reflected in Table 1 considering the Comparing the differences for the M –M4 materials regarding Young modulus, in Figure 3 the standard deviation of the experimental 2values. Considering the general mechanical behavior the curves almost overlap at the origin and that proximity is reflected in Table 1 considering the standard contribution of the chains accumulated in SI 60–100 for the modulus and SI 0–60 for the deformation deviation of the experimental values. Considering the general mechanical behavior the contribution of capacity, those mechanical properties for M1–M5 materials are plotted in Figure 4a,b, to show their the chains accumulated in SI 60–100 for the modulus and SI 0–60 for the deformation capacity, those trends with weight fraction of copolymer chains. In addition, since M4 and M5 show high weight mechanical properties for M1 –M5 materials are plotted in Figure 4a,b, to show their trends with weight fraction values in SI 40–60, their deformation values are also plotted for that interval (Figure 4b). In fraction of copolymer chains. In addition, since M4 and M5 show high weight fraction values in SI Figure 4a, the positive slope shows how the modulus increases as the weight fraction increases in the 40–60, their deformation values are also plotted for that interval (Figure 4b). In Figure 4a, the positive SI 60–100 interval. It can also be seen that the modulus difference is not very significant for M2, M3 and slope shows how the modulus increases as the weight fraction increases in the SI 60–100 interval. It can M4; however, looking at the ultimate strain in Figure 4b and Table 1, M2 and M3 show values close to also be seen that the modulus difference is not very significant for M2, M3 and M4 ; however, looking at each other, while M4 is considerable bigger than both of them (M4 shows 3.4 and 8.8 times the modulus the ultimate strain in Figure 4b and Table 1, M2 and M3 show values close to each other, while M4 is value of M2 and M3 respectively). This behavior clearly shows the synergic performance of M4, which considerable bigger than both in of Figure them (M shows 3.4 and 8.8 times the modulus value of M2 and M3 in fact can also be perceived 3 4looking at M 2–M4 curves, and comparing the toughness in respectively). behavior shows of M4 , which fact canslope also be Table 1, whereThis M4 shows 3.1clearly and 12.8 timesthe thesynergic value ofperformance M2 and M3 respectively. Theinpositive for perceived in Figure 3 looking at M –M curves, and comparing the toughness in Table 1, where 2 Figure 4 4 the deformation trend of the FCCs in 4b, that can be observed for both composition intervalsM (SI shows 3.1 and 12.8 times the value of M and M respectively. The positive slope for the deformation 2 3 0–60 and SI 40–60), denotes the importance of the presence of copolymer chains with intermediate trend of the FCCs in Figure 4b, that can be observed for both composition intervals (SI 0–60 and SI compositions. 40–60), denotesatthe of the presence of 3, copolymer chains with intermediate compositions. Looking theimportance reference materials in Figure the T-S polymer shows a low modulus compared Looking the similar reference materials incapacity Figure 3,tothe polymer shows a low modulus compared to four FCCsatand deformation MT-S 2, while the SC shows almost three times its to four FCCs capacity, and similar deformation to M2 , while almost times its deformation although it has acapacity lower modulus than the the SC T-Sshows material. Suchthree performances deformation capacity, although it has acopolymers lower modulus the T-Sproposed material.here Such performances validate the convenience to synthesize by thethan procedure and confirm that validate the convenience to synthesize copolymers by the procedure proposed here and confirm that in the T-S polymeric materials, the properties combination of the components is not promoted due to in the T-S polymeric materials, the properties combination of the components is not promoted due to phase separation of the homopolymers within the polymer bulk. phase separation of the homopolymers within the polymer bulk. 3300 M1 M2 M3 M4 M5 400 300 3000 SI 60-100 SI 0-60 SI 40-60 2700 Ultimate Strain (%) Young Modulus (MPa) 500 200 100 M1 M2 M3 M4 M5 2400 2100 100 80 60 40 20 0 0 0.0 0.2 0.4 0.6 0.8 Weight fraction of copolymer chains (a) 1.0 0.0 0.2 0.4 0.6 0.8 1.0 Weight fraction of copolymers chains (b) Figure 4. Young’s modulus and ultimate strain as a function of styrene weight fraction within FCCs Figure 4. Young’s modulus and ultimate strain as a function of styrene weight fraction within FCCs at at specific copolymer composition intervals. Young modulus SI 60–100; Ultimate strain specific copolymer composition intervals. (a) (a) Young modulus for for SI 60–100; (b) (b) Ultimate strain for for SI SI 0–60 and SI 40–60. For FCCs codes, see Figure 1. 0–60 and SI 40–60. For FCCs codes, see Figure 1. In Figure 5a, for the storage modulus (E’) of the two-component polymers it can be seen that the In Figure 5a, for the storage modulus (E’) of the two-component polymers it can be seen that the high value in SI 0–60 of the M5 copolymer promotes the E’ decay at low temperature, while the high high value in SI 0–60 of the M5 copolymer promotes the E’ decay at low temperature, while the high values in SI 60–100 and SI 80–100 of M1 impart the highest temperature resistance of the FCCs. The values in SI 60–100 and SI 80–100 of M1 impart the highest temperature resistance of the FCCs. The M2 M2 material follows closely the M1 trajectory up to 40 °C with an E’ decrease at slightly lower material follows closely the M1 trajectory up to 40 ◦ C with an E’ decrease at slightly lower temperature temperature due to its lower value for the SI 60–100, but mainly to its lower value in SI 80–100. The due to its lower value for the SI 60–100, but mainly to its lower value in SI 80–100. The E’ decay that M1 and M2 materials show at PBA Tg essentially correspond to the high value in SI 0–20, that both show in Figure 2a and Table 2. For the SI 0–30, the M3 copolymer that shows the highest value in Polymers 2017, 9, 72 8 of 11 E’ decay that M1 and M2 materials show at PBA Tg essentially correspond to the high value in SI 0–20, 8 of 11 that both show in Figure 2a and Table 2. For the SI 0–30, the M3 copolymer that shows the highest value in Table 2 presents a steeper E’ decay that starts slightly above PBA Tg, but its high value in SI Table 2 presents steeper resistance E’ decay that starts aboveE’PBA its80 high 80–100 allows aathermal before theslightly catastrophic finalTdecay °C.value in SI 80–100 g , but at allows a thermal resistance before the catastrophic E’ final decay at 80 ◦ C. Polymers 2017, 9, 72 1000 M1 M2 M3 M4 M5 T-S SC 1000 Loss modulus (MPa) Storage modulus (MPa) 10000 100 M1 M2 M3 M4 M5 T-S SC 100 10 10 1 -60 -40 -20 0 20 40 60 Temperature (°C) (a) 80 100 120 -60 -40 -20 0 20 40 60 80 100 120 Temperature (°C) (b) Figure5.5.(a) (a)Storage Storagemodulus; modulus;and and(b) (b)loss lossmodulus modulusasasa afunction function temperature for: FCCs 1–M5), Figure ofof temperature for: FCCs (M(M 1 –M5 ), T-S and SC materials (frequency: 1 Hz). For codes, see Figures 1 and 2. T-S and SC materials (frequency: 1 Hz). For codes, see Figures 1 and 2. The M4 copolymer does not show a phase separation tendency in E’, starting a smooth decay at The M copolymer does not show a phase separation tendency in E’, starting a smooth decay at 0◦ °C and, 4around 40◦ °C it presents a crossover point with the M3 curve, denoting a slightly higher 0 C and, around 40 C it presents a crossover point with the M3 curve, denoting a slightly higher temperature resistance for the latter material, when both approach the terminal zone for E’. The SC temperature resistance for the latter material, when both approach the terminal zone for E’. The SC shows very poor temperature resistance for the E’ value, while the T-S shows a marked decay at PBA shows very poor temperature resistance for the E’ value, while the T-S shows a marked decay at PBA Tg (more than one order of magnitude) followed by a plateau that starts at −20 °C that presents a Tg (more than one order of magnitude) followed by a plateau that starts at −20 ◦ C that presents a final decay close to 100◦ °C. Its low E’ performance as in the static test can be attributed to the lack of final decay close to 100 C. Its low E’ performance as in the static test can be attributed to the lack of interaction between components. interaction between components. For loss modulus (E”) in Figure 5b, the M5 FCC shows a copolymer type behavior with a peak at For loss modulus (E”) in Figure 5b, the M5 FCC shows a copolymer type behavior with a peak at approximately 10 °C with an almost vertical decay afterwards, denoting an elastomeric behavior at approximately 10 ◦ C with an almost vertical decay afterwards, denoting an elastomeric behavior at room temperature. M1 and M2 copolymers follow very similar trajectories (as in E’ behavior) in the room temperature. M1 and M2 copolymers follow very similar trajectories (as in E’ behavior) in the whole test temperature range. The peak around −40◦ °C is assigned to a glass transition response, due whole test temperature range. The peak around −40 C is assigned to a glass transition response, due to the chains accumulated in the SI 0–20 (Figure 2a); then, E” maintains a certain plateau value, until toitthe chains in thewith SI 0–20 (Figure 2a); then, certain plateau value, until falls at 80◦ accumulated °C, in accordance E’ decay (Figure 5a).E” M3maintains material, ashows a wide peak at −25 °C, ◦ C, itbecause falls at 80 C, in accordance with E’ decay (Figure 5a). M material, shows a wide peak at − 25 3 0–20; then, it shows a smooth decay as there are a considerable amount of chains in the SI it because there are a considerable amount of chains in the SI 0–20; then, it shows a smooth decay as it did in the E’ curve (Figure 5a). At around 40 °C, it starts a plateau like behavior due to the influence did in the curveuntil (Figure 5a). At around 40 ◦ C, it starts a80plateau like behavior due to the influence of of the SI E’ 60–100, its final decay at approximately °C. ◦ C. the SI The 60–100, until its final decay at approximately 80 M4 material shows a very wide peak from −40◦ to 40 °C (the widest of all polymeric The M material shows a very wide peak from − 40 to 40 widest of of all compositions polymeric materials) materials)4 indicating the presence of copolymer chains withC a(the wide range around indicating the presence of copolymer chains with a wide range of compositions aroundby thethe highest the highest peak value (approximately at −11 °C); that trajectory is highly influenced chains ◦ C); that trajectory is highly influenced by the chains composition peak value (approximately at − 11 composition profile in the SI 0–70 range. The slow decrease of E” that starts at ca. 0 °C continuous profile SI 0–70a range. The formation slow decrease of E” that starts ca. 0 ◦ is C continuous until it presents until in it the presents shoulder tendency at 60 °C,atwhich a signal influenced by the ◦ a accumulation shoulder formation tendency at 60 C, which is a signal influenced by the accumulation chainsat of chains in the SI 70–100 range (chains rich in S); the final modulus decayofoccurs inlower the SItemperature 70–100 range (chains rich in S); the final modulus decay occurs at lower temperature than than M1–M 3 materials due to its lower SI 70–100 value. The high E” value from ◦ C, M−55 materials due to its lower SI value.dissipation The high E” value from 55 ◦ C the to almost 1 –M 3 °C to almost 40 °C, indicates a 70–100 high energy capacity (area−under curve) 40 within indicates a high energy capacity (area under thepresents curve) within that temperature range. that temperature range.dissipation For the reference materials, the SC a copolymer type behavior with For the reference materials, the SC presents a copolymer type behavior with a lower but slightly wider a lower but slightly wider peak than the one presented by M5 (accounting for the dissipation capacity peak than one presented M5 (accounting for the dissipation capacity since −the 60 ◦random C), that deviates since −60the °C), that deviatesby slightly at 20 °C towards its final decay, denoting structure ◦ C towards its final decay, denoting the random structure with very low temperature slightly at 20 with very low temperature resistance. The T-S material shows a peak at −45 °C showing a ◦ C showing a temperature peak value close to PBA resistance. Thepeak T-S material shows a peak at −45 temperature value close to PBA Tg with a significant E” decay (due to is high PBA content) that Tis a significant E” decay (due high content) that is followed by a plateau fromthe 0 toglass ca. g with followed by a plateau from 0 to to isca. 100PBA °C (showing there a small peak), denoting ◦ 100 C (showing there a values small peak), denotingthe theones glass temperature values that resemble transition temperature that resemble oftransition the pure homopolymers. the ones of the pure homopolymers. Polymers 2017, 9, 72 9 of 11 In summary, the methodology proposed here to design the properties of a FCC by variations in the WCD of the chains and its correlation with the mechanical properties has been demonstrated, showing also an unusual failure envelope involving diverse mechanostatic performances of copolymers obtained using the same chemical system and global comonomer composition, tested at the same temperature and cross head speed. Additionally, as stated in this work, the correlation between WCD profiles and the mechanical properties above described using FRP reactions (establishing the structure characteristics required for synergic behavior) has an equivalent with controlled radical polymerization (CRP). Recently, for the S/BA system using also a semicontinuous emulsion process with a multistage feeding technique [18–20]), Guo et al. tested two types of gradient copolymers obtained by CRP that exhibited yielding and elastic deformation [24], whose copolymer chains composition varied from one component to the other, according to their former report [25]. Although they did not present a discussion about their behavior related to the specific structures of those gradient copolymers, the explanation for that behavior is in accordance with the synergic contribution of the components proven here (as it was also demonstrated in chemical blends); the presence of long segments of each one of the components along with transition chain segments of intermediate compositions of monomers A and B in between each molecule, should lead to the optimization of polymer properties. The conformed polymer bulk would be similar to the copolymers above described using FRC. In another report, similar results on damping performance were found for materials obtained by FRC [20] and CRP [21] for the S/BA system. The equivalence in properties has to do with the richness in S and BA units. For the FRC case, such richness occurs in different chains, and for the CRP case it occurs within one molecule. Such component richness in high MW chains is important for mechanical properties in both cases, because the contribution of each component is enhanced in that way; it is well known that MW is an important parameter for mechanical properties [26,27]. Additionally, the polydispersity index should also be considered if looking for uniform properties in the product [28], or for easy processing, particularly for high MW polymers [29]. To improve the synthesis processes, the use of programmed feeding can help to control comonomer addition in FRC [30] or CRP [31,32]. 4. Conclusions The WCD-bulk mechanical properties relationship for FCCs obtained by FRP has been demonstrated. Additionally, it has been shown that the WCD can be easily modified by variations in the comonomer feeding profile if a semicontinuous emulsion polymerization is used (taking into consideration the specific monomer reactivities). The wide failure envelope obtained confirms that the methodology presented here can be used to tailor copolymer properties using a reaction system that can easily be extended to industrial scale for a wide variety of applications. Acknowledgments: financial support. The authors wish to thank CONACYT and Universidad de Guadalajara for the Author Contributions: Carlos Federico Jasso-Gastinel: Conceived the experiments, codesigned the reactions, analyzed data, and wrote the paper. Alvaro H. Arnez-Prado; Francisco José Aranda-García; Luis Octavio Sahagún-Aguilar: Performed the experiments and part of the characterization. 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