The successful application of poly(N-vinylcaprolactam)-based microgels requires a profound understanding of their synthesis. For this purpose, a validated process model for the microgels synthesis by precipitation copolymerization with the cross-linker N,N′-methylenebis-(acrylamide) is formulated. Unknown reaction rate constants, reaction enthalpies, and partition coefficients are obtained by quantum mechanical calculations. The remaining parameter values are estimated from reaction calorimetry and Raman spectroscopy measurements of experiments with different monomer/cross-linker compositions. Because of high crosspropagation reaction rate constants, simulations predict a fast incorporation of the cross-linker. This agrees with reaction calorimetry measurements. Furthermore, the gel phase is predicted as the major reaction locus. The model is utilized for a prediction of the internal particle structure regarding its crosslink distribution. The highly cross-linked core reported in the literature corresponds to the predictions of the model.

Functional microgels with tailored structure and specific properties are required for medical and technical applications, thus motivating model-based optimization of their fabrication processes. An important step in the creation of accurate models is parameter estimation. We present a methodology for a parameter identifiability analysis, which approximates the feasible parameter set as a box by solving a series of constrained dynamic optimization problems. The method is applied to the synthesis of microgels based on two monomers, N-vinylcaprolactam and N-isopropylacrylamide, and the cross-linker N,N-methylenebis(acrylamide). The results show that kinetic parameters corresponding to the reaction of the monomers are identifiable as are a subset of the kinetic parameters involving the cross-linker. The reaction kinetics of the cross-linking are faster in comparison to the main polymerization reaction for N-vinylcaprolactam; this allows for an improved understanding of the occurring reaction phenomena. The reaction kinetics of the cross-linking are not identifiable for N-isopropylacrylamide for the given experimental setup; model-based experimental design for parameter precision might enable their identification. The results also indicate potential for model simplification and allow us to make suggestions toward the enhancement of Raman spectroscopy measurements.

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Particle size distribution and in particular the mean particle size are key properties of microgels, which are determined by synthesis conditions. To describe particle growth and particle size distribution over the progress of synthesis of poly(N-vinylcaprolactam)-based microgels, a pseudo-bulk model for precipitation copolymerization with cross-linking is formulated. The model is fitted and compared to experimental data from reaction calorimetry and dynamic light scattering, showing good agreement with polymerization progress, final particle size, and narrow particle size distribution. Predictions of particle growth and reaction progress for different experimental setups are compared to the corresponding experimental data, demonstrating the predictive capability and limitations of the model. The comparison to reaction calorimetry measurements shows the strength in the prediction of the overall polymerization progress. The results for the prediction of the particle radii reveal significant deviations and highlight the demand for further investigation, including additional data.

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