Role of grafting in the emulsion polymerization of vinyl acetate with poly(vinyl alcohol) as an emulsifier. I. Effect of the degree of blockiness on the kinetics and mechanism of grafting

The role of grafting in particle nucleation during the emulsion polymerization of vinyl acetate with partially hydrolyzed poly(vinyl alcohol) (PVA) as an emulsifier and potassium persulfate as an initiator was investigated. The polymerizations were carried out in batch with a low solids (10%) recipe. An automated reaction calorimeter (Mettler RC1) was used for the direct monitoring of the kinetics of emulsion polymerizations with three medium molecular weight PVAs differing in their degrees of blockiness (Poval 217EE > 217E > 217). Smith–Ewart case 1 kinetics (average number of free radicals per particle < 0.5) were followed in all cases, and no constant rate in interval II was observed. Contrary to what was expected, a nonlinear relationship was observed between the rate of polymerization ( R p ) and the number of particles ( N p ). At R p max, N p (217E) > N p (217EE) > N p (217), and the final N p was independent of the degree of blockiness of PVA. The particle size distributions were broad (particle diameter = 20–100 nm) and bimodal. On the basis of these data, we concluded that particle nucleation was continuous and was accompanied by extensive limited aggregation during the particle growth stages. The evolution of the amounts of grafted PVA and poly(vinyl acetate) (PVAc) were determined in polymerizations employing the two PVAs differing the most in blockiness (Poval 217EE and 217). The grafted PVAc followed similar profiles, increasing with conversion, particularly near the end of the two reactions. The amounts of grafted PVAc were about the same in the final latexes (37–39%). In contrast, the grafting of PVA was nearly complete by the time monomer droplets had disappeared in each reaction (25% conversion). However, the extent of grafting differed significantly, with the blockier PVA having about one‐third the grafting of the more random PVA (∼10% vs ∼30%). In these low solids recipes, grafting appeared to be primarily a solution event, occurring predominantly in the aqueous phase and not at the particle/water interface, as was previously speculated. The PVAc grafts grew until the molecules became water‐insoluble and precipitated, forming polymer particles. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 3633–3654, 2001