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Announcing: The 36th Annual Short Course"ADVANCES IN EMULSION POLYMERIZATION AND LATEX TECHNOLOGY"This is a One-Week Short Course that will be offered by the Emulsion Polymers Institute (EPI) at Lehigh University in Bethlehem, Pennsylvania USA on June 6-10, 2005. Details of the course are given below.
COURSE ORGANIZER: Dr. Mohamed S. El-Aasser For more information, or to request a printed course brochure and
registration form, please contact: Note: You may also download a registration form using the links given below to reserve your space in the 2005 Short Course. Credit cards (Visa, MasterCard or American Express) can be used to charge the course registration fee and University housing fees.
The course is an in-depth study of the synthesis, characterization, and properties of high polymer latexes. The subject matter includes a balance of theory and applications as well as a balance between chemical and physical problems. Lectures will be given by leading academic and industrial workers. Lectures will begin with introductory material and reviews, and will progress through recent research results.
Sinclair Laboratory Auditorium Lectures will start at 8:30 A.M. Monday to Thursday.
TENTATIVE LECTURE/COURSE SCHEDULE
FOR 2005 SHORT COURSE
MONDAY, JUNE 6, 2005 Breakfast – Brodhead House Lecture 1 – Kinetics of Free Radical-Initiated Polymerization
(F. Joseph
Schork) Lecture 2 – Emulsion Polymerization Mechanisms and Kinetics
(Gary W. Poehlein) Lunch – Brodhead House Lecture 4 – Industrial Uses of Latexes (Do Ik Lee) EVENING: Campus Pizza Mixer
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 | Comfort Suites (*) 610-882-9700 |
| Hampton Inn & Suites at the Gateway 610-868-2442 |
| Holiday Inn Bethlehem at the Gateway 610-866-5800 |
| Radisson Hotel Bethlehem 610-625-5000 |
| Marriott (Residence Inn, Courtyard or Fairfield Inn; Motel Drive,
Bethlehem; 800-321-2211 * This facility which is located two blocks away from Sinclair Laboratory, is the only hotel within walking distance of the university. EDITED TO HERE 11/22/04 |
Click here to download a 2005 Short Course Registration Form in Word (Windows) format
Click here to download a 2005 Short Course Registration Form in Adobe PDF format
COURSE OUTLINE:
MONDAY, JUNE 6, 2005
1. Kinetics of Free Radical-Initiated Polymerization--
F. Joseph Schork (Georgia Institute of Technology)
A review of the principles of free radical-initiated polymerization,
including the four basic reactions of initiation, propagation, termination and transfer,
inhibition, molecular weight and molecular weight distribution, effect of temperature and
pressure, autoacceleration and diffusion control of termination and propagation, and
copolymerization including copolymerization reactivity ratios and copolymer sequence
distribution.
2. Emulsion Polymerization Mechanisms and Kinetics--
Gary W. Poehlein (Formerly with Georgia Institute of Technology)
Reaction mechanisms and kinetics of free radical polymerization will
be reviewed. The unique features of emulsion polymerization will be outlined and the
influence of the colloidal size of the reaction sites discussed. Kinetic theories due to
Smith & Ewart, Stockmayer, O'Toole, Roe, Fitch, Ugelstad, and Gilbert will be
discussed.
3. The Role of Surfactants in Emulsion Polymerization Processes--
Mohamed S. El-Aasser (Lehigh University)
Surfactants play major roles during the particle nucleation and
growth stages, with direct impact on latex particle size, size distribution,
polymerization rate, molecular weight, and particle morphology. Surfactants are also
essential during post-polymerization processes: stripping, storage, shipping, and
formulation for several applications. The general characteristics of surfactants and their
adsorption profiles on latex particles will be reviewed. The specific role of surfactants
in determining the particle number according to the various nucleation mechanisms will be
described. Three alternatives to conventional surfactants will be reviewed.
4. Industrial Uses of Latexes--
Do Ik Lee (Formerly with The Dow Chemical Company)
About 10 million metric tons of latex polymers are being used annually in a very large number of industrial applications: paints and coatings (architectural, industrial, maintenance, elastomeric, etc.) (~26% of the total latexes used), paper and paperboard applications (wet-end additives, sizing, and coatings) (~24%), adhesives (packaging, furniture and wood fabrication, and pressure-sensitive, consumer glues, and building/construction) (~23%), carpet backsizing (~10%), textile and nonwovens, caulks and sealants, surgical gloves, foams, cement additives, asphalt additives, biomedical, flocculents, rheology modifiers, etc. This talk will briefly review some of their major applications and the types of latexes used for those applications. The requirements and needs for those applications will be also discussed along with the recent developments in latex technologies.
TUESDAY, JUNE 7, 2005
5. Stabilization Mechanisms in Aqueous and Non-Aqueous Latexes--
Mohamed S. El-Aasser (Lehigh University)
The basic concepts and terminology of colloid science will be
introduced. The principles of electrostatic and steric stabilization mechanisms will then
be reviewed. The inverse problem of coagulating and flocculating latexes will also be
discussed.
6. Engineering of Emulsion Polymerization Reactors--
Gary W. Poehlein (Formerly with Georgia Institute of Technology)
The various types of reactors: batch, semi-batch and continuous,
used to produce synthetic latexes, will be reviewed. Pros and cons of various types of
processes will be discussed and theoretical reactor models will be presented where
appropriate. Reactor design and operating factors that influence product properties will
also be reviewed.
7.
Semi-Continuous Emulsion Polymerization and Structured Latexes--
Michael
F. Cunningham (Queen's University)
Semi-continuous (or semi-batch) polymerizations in which the monomer is added
incrementally during the course of reaction are commonly used in industrial
processes because they allow control of the polymerization rate, and because
they can be used to control the particle morphology. “Structured latexes”
are emulsion polymer particles in which the internal morphology and/or
composition vary through the particle. Examples include core-shell particles,
and particles with radial composition gradients between the particle core and
surface. The discussion will describe how semi-continuous processes are run, the
unique features of operating an emulsion polymerization in semi-continuous mode,
and how structured latexes can be synthesized.
8. Details of Emulsion Polymerization through Reaction Calorimetry--
E. David Sudol (Lehigh University)
Emulsion polymerization kinetics is usually
reported in the form of conversion-time behavior. The rate of polymerization is
obtained by differentiation, which can introduce significant noise and obscure
details of the reaction. Reaction calorimetry provides a more direct measurement
of the rate of polymerization through measurement of the heat of reaction. Its
use in investigating the mechanisms of emulsion polymerization will be
presented. Fundamental work on the emulsion polymerization of styrene will be
reviewed and deviations from ‘classical’ behavior will be highlighted.
Further examples will be given as to how this methodology is being applied to
gain mechanistic understanding of other emulsion polymerization systems.
WEDNESDAY, JUNE 8, 2005
9. Advances in Miniemulsion Polymerization--
Mohamed S. El-Aasser (Lehigh University)
Despite the fact that the first
miniemulsion polymerization was carried out at Lehigh University in 1972, the
term "miniemulsion" was first coined only in 1981. The number of
publications on miniemulsions has been increasing exponentially over the past
decade, including a few patents.
Miniemulsions are relatively stable oil-in-water emulsions with average droplet diameters ranging from 50 to 500 nm. These are typically prepared using a mixture of a surfactant and a low molecular weight, highly water-insoluble costabilizer (sometimes referred to as cosurfactant). In miniemulsion polymerization, the submicron monomer droplets are the main sites for particle nucleation and growth via free radical initiation using oil-soluble or water-soluble initiators. The stability behavior of miniemulsions has been explained theoretically based on the well know concepts of Ostwald ripening and thermodynamics. Miniemulsions have been exploited in making new types of polymer colloids (latexes) that were difficult and sometimes impossible to make using conventional emulsification or emulsion polymerization processes. These include preparation of artificial latexes and hybrid latexes, high solids latexes, polymerization of highly water-insoluble monomers and macromonomers, controlled polymer microstructure and morphology, encapsulation of pigments and dyes, and controlled molecular weight via living free radical polymerization. In this lecture both the theory and practice of miniemulsions will be discussed.
10. Experimental Methods for the Characterization of Latex Particle Size
and Particle Size Distribution --
Cesar A. Silebi (Lehigh University)
The application of fractionation and non-fractionation methods for the
determination of particle size
distribution, the range of applicability, and advantages and disadvantages and
their on-line measurement capability will be discussed.
Among the methods examined are: classical and dynamic light scattering,
sedimentation, disc centrifugation, electrozone sensing, sedimentation field
flow fractionation, capillary hydrodynamic fractionation, and recent advances in
hybrid methods of analysis. Comparisons
of several of these methods will be used to illustrate problems often
encountered in the particle size distribution determination of latexes.
11. High Solids Latex Technology--Do Ik Lee (Formerly with The Dow Chemical Company)
High-solids latex technology is based on two basic principles: the maximization of latex particle packing and the minimization of the effective volumes of latex particles from the viewpoints of dispersion rheology. With these two principles at hand, the technology is concerned with the maximization of the volume solids of latexes, while meeting their respective end-use property requirements for a variety of applications. For this reason, although the technology is capable of achieving 70% or higher volume solids latexes, its objective is to increase the volume solids of the existing latexes by 5% to 15% by considering only a bimodal approach for the packing efficiency. This talk will describe the basic principles involved in the high-solids dispersion technology, and then discuss blending (i.e., large and small particle size latex blends) and in-situ (i.e., by either surfactant or seed addition during polymerization) methods of preparation for high-solids bimodal latexes.
12. Sensors and Control of Emulsion Polymerization Reactors--
F. Joseph Schork (Georgia Institute of Technology)
Recent developments in the area of on-line sensors, coupled with the
availability of high-performance digital control systems, have opened up new opportunities
for the efficient operation and control of latex reactors. Available sensors for on-line
analysis will be discussed. The use of such measurements in the application of advanced
control techniques to batch and continuous polymerization reactors will be reviewed, with
special emphasis on controlling the undesirable process dynamics associated with
continuous emulsion polymerization, and optimizing controllers for batch polymerization.
13. Advanced Research Topics in Emulsion Polymerization and Latexes: An Evening
Poster Session--
Graduate
Students in the Emulsion Polymers Institute, Lehigh University.
THURSDAY, JUNE 9, 2005
14.
Living-Controlled Radical Polymerization in Bulk, Emulsion, and
Miniemulsion-- Michael
F. Cunningham (Queen's University)
“Living”
(or “controlled”) radical polymerizations provide a novel and potentially
inexpensive route to designing polymers with controlled microstructure (e.g.
block copolymers, star polymers) and narrow molecular weight distributions.
While extensive research has been conducted into homogeneous bulk and solution
living radical polymerizations, investigations into aqueous dispersed phase
systems (emulsion and miniemulsion polymerization) have only recently appeared.
Although little progress has been realized with emulsion polymerization,
considerable success has been achieved using miniemulsion polymerization with
living radical systems. This presentation introduces the three major living
radical polymerization chemistries (nitroxide-mediated radical polymerization (NMRP),
atom transfer radical polymerization (ATRP) and
reversible-addition-fragmentation-transfer polymerization (RAFT)), and
summarizes recent progress of these systems in bulk, miniemulsion and emulsion.
The emphasis will be on heterogeneous systems, and more specifically on
those aspects of operating in a heterogeneous environment that influence the
polymerization rate, the molecular weight distribution and the livingness of the
system.
15. Film Formation and Cohesive Strength Development from Latex
Systems--
Andrew Klein (Lehigh University)
The cohesive properties of polymer films from latexes are dependent on the film
formation mechanism. Polymer film formation from latex occurs either when: (a) the
molecules from the individual polymer particles interdiffuse and entangle as the particle
boundaries gradually disappear; or, when (b) the molecules partially interpenetrate and
cross-link, forming interparticle "spotwelds"; or when (c) water-soluble
molecules react or interact with functional groups on the particle surface. In the last
two cases, the particle boundaries remain distinct. The role of interpenetration depth and
the diffusion rate on cohesive strength development will be discussed, using model latex
systems.
16. Latex Rheology--
Cesar A. Silebi (Lehigh University)
Review
of experimental studies illustrating the various factors that influence the
rheological properties of latexes. Topics to be covered include the effects of
solids concentration, particle size and distribution, electrolyte content,
particle aggregation, adsorbed surfactants, non-spherical particle morphology,
particle swelling, and the use of water-soluble associative and non-associative
polymeric thickeners. Consideration will also be given to thickened latexes and
variables affecting their rheological flow curves.
17. Mixing Scale-Up in Emulsion Polymerization--
Andrew Klein (Lehigh University)
Scale-up of the mixing process in emulsion polymerization involves
breaking the process down into individual but interrelated steps. The effect of mixing on
the microscopic heterogeneity of the continuous phase, fluid shear rates and heat transfer
allows each to be considered separately. A few of these effects will be discussed and
illustrated with specific examples. The utility of bench scale experimentation, using an
impeller-modified reaction calorimeter (Mettler RC1), with a view toward scale-up with
some early experimental results, will also be discussed.
FRIDAY, JUNE 10, 2005
18.
Future Directions for Polymer Colloids--Michael
F. Cunningham (Queen's University)
While
significant advances have occurred in emulsion polymerization in recent decades,
in both our fundamental understanding and in practice, two features have not
changed much. First, the monomers used to make emulsion polymers have been
primarily those readily polymerized by a free radical mechanism. Second, the
range of applications has remained largely confined to traditional areas such as
coatings and adhesives. However in recent years two major trends have become
apparent, one related to the types of applications found for polymer colloids,
and the other for the types of monomers that may be used. Polymer colloids are
increasingly being used for a variety of applications outside traditional areas,
including fields such as health sciences, microelectronics and information
technology. This presentation will give an overview of these areas. Even more
significant for the future however, are the rapid advances currently being made
in macromolecular chemistry that allow synthesis of polymer colloids using
monomers not previously polymerizable in water-based systems. These polymers are
often not based on a free radical mechanism. As this chemistry matures, new
classes of polymer colloids will emerge, possibly ushering in entirely new
fields of application and considerable opportunities for product innovation. An
overview of these emerging techniques will be presented, along with specific
examples.
19. Mechanisms and Examples of Crosslinking in Latex Systems--
Eric S. Daniels (Lehigh University)
The chemistry and technology of crosslinking in latex systems and
their relationship to the latex film formation process and cohesive strength development
in polymer films will be reviewed. Special emphasis will be placed on the crosslinking
mechanisms (homogeneous, interfacial, and interstitial) which arise when a variety of
functional groups such as carboxyl, N-methylolacrylamide derivatives, hydroxyl, epoxy, or
isocyanate are incorporated into the latex particles. Recent research results on
crosslinking and film formation in both conventional and miniemulsion latex systems
containing dimethyl meta-isopropenyl benzyl isocyanate (TMI®) will be presented.
20. Thermally Expandable Microspheres--
Andrew Klein (Lehigh University)
Thermally-expandable particle technology dates back to the 1960s. A survey of
the patent literature indicates an exponential growth phase for the past 5 to 10
years in the number of new patents granted for new uses and synthesis. In this
talk the synthesis aspects: particle stabilization, particle morphology,
particle size control, and characterization of the expandable particles for
their thermal response for expansion and collapse will be described.
LECTURERS:
Michael F. Cunningham-- Associate Professor within the
Department of Chemical Engineering, Queen’s University, Kingston, Ontario,
Canada. He received his Ph.D. in
1990 from the University of Waterloo where he studied chemical engineering with
Prof. K.F. O’Driscoll. Prior to his joining Queen’s University, he was with
the Xerox Research Centre of Canada for six years.
While there he conducted research into the design of composite polymer
particles. He was co-inventor of a
novel composite particle that is now a critical component of the xerographic
developer in Xerox copiers and printers. This work has led to 25 U.S. patents.
Among his research interests are the areas of polymer reaction
engineering, emulsion/miniemulsion polymerization, and living radical
polymerization.
Eric S. Daniels-- Principal Research Scientist and Executive Director, Emulsion Polymers Institute, Lehigh University. Received his Ph.D. in Polymer Science and Engineering from Lehigh University in 1987. Research interests include the biomedical applications of latexes, the mechanism for the formation of composite latexes, particle morphology, interfacial crosslinking and film formation in emulsion polymer systems, particle technology, and the role of surfactants in emulsion polymerization.
Mohamed S. El-Aasser-- Provost, Lehigh University, and formerly Dean, P.C. Rossin College of Engineering and Applied Science and Director of the Emulsion Polymers Institute, Lehigh University. Ph.D. from McGill University and Pulp and Paper Research Institute in 1972. Research interests include emulsion polymerization, emulsification, surface and colloidal properties of latexes, latex film formation, adsorption from solutions, and stabilization of colloids.
Andrew Klein-- Professor of Chemical Engineering, Lehigh University. Ph.D. in Chemical Engineering from North Carolina State University at Raleigh. Industrial experience in emulsion polymers with GAF and National Starch and Chemical Company. Research interests include colloid and surface chemical aspects of heterogeneous polymerization kinetics, related thermodynamics, engineering and applications.
Do Ik Lee--
B.
S. degree in Chemical Engineering from
Gary W. Poehlein-- Professor Emeritus of Chemical Engineering, Georgia
Institute of Technology. Ph.D. in Chemical Engineering from
F. Joseph Schork-- Professor of Chemical Engineering, Georgia Institute of Technology. Ph.D. in Chemical Engineering from the University of Wisconsin working in the field of emulsion polymerization reactor dynamics. Industrial experience with E.I. DuPont de Nemours & Company in the areas of emulsion polymerization and digital process control. Research interests in polymerization reaction engineering, digital control of polymerization reactors, system dynamics and nonlinear control. Consultant to various companies in the area of polymerization reaction engineering.
Cesar A. Silebi-- Professor of Chemical Engineering at Lehigh
University. Ph.D. from Lehigh University. Research interests include particle
separation processes, rheological and colloidal properties of latexes,
multi-component transport in emulsions, and stability of colloidal systems.
E. David Sudol-- Principal Research Engineer and Associate Director
for Research, Emulsion Polymers Institute,
Lehigh University. Ph.D. in Chemical Engineering from Lehigh University. Research
interests include emulsion polymerization kinetics and mechanisms, reactor design,
reaction modeling, and characterization of latexes.
Send mail to Eric.Daniels@Lehigh.edu with questions or comments about this web site.
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