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A good working knowledge of the mechanism and an appreciation of the effects the process variables have on the properties of interest are required for optimization and control of polymerization processes. Despite the importance of ethylene‐vinyl acetate emulsion copolymers, limited kinetic information is available. Results from a series of factorial experiments are presented here which examine the emulsion polymerization of ethylene with vinyl acetate. Copolymers of up to 32 wt % ethylene have been produced at an ethylene pressure of 500 psig and a temperature of 20°C. The effects of the process variables on the rate of polymerization, copolymer composition, particle size and number, molecular weight averages, and gel content are discussed. The kinetic results obtained suggest process improvements for the production of homogeneous copolymer. Mechanistically, the locus of polymerization has been verified as the polymer particles and little water phase polymerization was observed. © 1993 John Wiley & Sons, Inc.

Ethylene–vinyl acetate emulsion copolymers are useful materials for paint, adhesive, and coating applications. The kinetics of their production remain largely unstudied, probably due to the inherent difficulties associated with pressure polymerizations. Polymerizations at elevated pressures are in general more difficult to understand and control, and relatively more expensive since one has to consider the added cost of increased safety precautions. Reported here are the preliminary results of an extensive experimental investigation of the variables which govern the ethylene–vinyl acetate emulsion process. Two redox initiator systems have been identified as more suitable for the polymerization process. Two buffer systems, namely sodium acetate/acetic acid and potassium phosphate, have been used to effectively control pH. The addition of n‐hexane has offered an effective method of enhancing the ethylene content in the copolymer produced. Several other important variables including agitation/mixing and emulsifier type and concentration have been identified and are discussed. These screening experimental observations have aided in the selection of suitable design levels for future, more focused experimentation to quantify the effects of reaction variables on the latex and copolymer properties of interest. A review of the existing literature on ethylene–vinyl acetate copolymer properties and processes is also included. © 1993 John Wiley & Sons, Inc.

Brominated (BIIR) and chlorinated (CIIR) poly(isobutylene-co-isoprene) are commercially available materials commonly known as halobutyl rubbers. The effect of leaving-group ability on the reactivity of halogenated poly(isobutylene-co-isoprene) was studied to place iodobutyl rubber reactivity into context with these materials. The effect of microstructure on reactivity of existing commercial materials was studied through comparison to that of polymers containing rearranged halomethyl (r-CIIR, r-BIIR, and r-IIIR) microstructure (prepared from as-received BIIR). The effect of leaving group on both thermal stability and reactivity towards nucleophilic substitution with acetate, N-butylimidazole, and sulfur was examined. The material containing the iodomethyl microstructure (r-IIIR) readily underwent nucleophilic substitution at low temperatures; however, it was extremely sensitive towards dehydrohalogenation at temperatures above 65 °C. At temperatures between 100 and 135 °C, the material containing the bromomethyl microstructure (r-BIIR) demonstrated the greatest balance between reactivity toward nucleophilic substitution and elimination through dehydrohalogenation. Exceptional thermal stability at temperatures up to 190 °C was displayed by the material containing the chloromethyl microstructure (r-CIIR); however, its reactivity towards nucleophiles was variable and nucleophile dependent. Sulfur vulcanization studies showed a clear effect of microstructure on the ability to cure with sulfur. While commercial chlorobutyl rubber has no ability to cure with sulfur alone, when rearranged to its chloromethyl microstructure (r-CIIR), curing occurs readily. Both commercial (BIIR) and rearranged (r-BIIR) bromobutyl rubber readily vulcanize in the presence of sulfur; however, BIIR cures to a greater extent.

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