Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F112/00—Homopolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring
  • C08F112/02—Monomers containing only one unsaturated aliphatic radical
  • C08F112/04—Monomers containing only one unsaturated aliphatic radical containing one ring
  • C08F112/06—Hydrocarbons
  • C08F112/08—Styrene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F12/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring
  • C08F12/02—Monomers containing only one unsaturated aliphatic radical
  • C08F12/04—Monomers containing only one unsaturated aliphatic radical containing one ring
  • C08F12/06—Hydrocarbons
  • C08F12/08—Styrene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F2/00—Processes of polymerisation
  • C08F2/04—Polymerisation in solution
  • C08F2/06—Organic solvent
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F2/00—Processes of polymerisation
  • C08F2/38—Polymerisation using regulators, e.g. chain terminating agents, e.g. telomerisation
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F2438/00—Living radical polymerisation
  • C08F2438/01—Atom Transfer Radical Polymerization [ATRP] or reverse ATRP

Definitions

• the present invention relates to a process for the synthesis of vinyl aromatic polymers, in which the sequence of monomers in the chain and the linear, branched soluble, or crosslinked insoluble structure, with reactive or different polarity functions, can be controlled.
• the polymers thus produced can be used as such or can be used for producing block polymers, without the use of poly-functional initiators, which can generate three or more polymer chains, without the use of polyvinyl monomers or inimers used to obtain branched polymer structures, at contained costs thanks to the use of low concentrations of complex catalyst and low component costs.
• ARGET-ATRP Atom Transfer Radical Polymerization
• Said process can be applied to the synthesis of linear, branched, block and functionalized vinyl aromatic polymers to be used as such. Said process can further be applied for making compatible polymer compositions containing vinyl aromatic and other
• incompatible polymers for the preparation of vinyl aromatic compositions with reactive, adhesive, flame retardant, anti-static or bactericidal functions.
• a polymer with a crosslinked structure means an insoluble polymer, at the most swelling with the monomer or with a suitable solvent even if covalent chemical bonds are not identified between the chains.
• polymers with a branched structure are soluble polymers that display polydispersity provided by the ratio between the weight average molecular mass (Mw) and the number average molecular mass (Mn) indicated with Mw/Mn greater than 2 and Mw determined with viscosimetric detection or Multi Angle Laser Light Scattering (MALLS) greater than 20% with respect to Mw determined with refraction index detection, even if no covalent chemical bonds are identified in the branching points between the chains.
• Polymers with a linear chain are polymers in which Mw determined with viscosimetric detection or Multi Angle Laser Light Scattering
• MALLS is about equal to a maximum of 20% greater than Mw determined with refraction index detection.
• (meth)acrylic means an acrylic or methacrylic compound
• (bi)carbonate means a carbonate or bicarbonate compound
• ATRP Atom Transfer Radical Polymerization
• ARGET Activator ReGenerated by Electron Transfer
• a polymerization process in which copolymerizable monomers can be polymerized in the presence of a reducing agent and a polymerization means that initially comprises a catalyst with at least one transition metal and a radical initiator, in which the molar ratio between transition metal and radical initiator is less than 0.05, up to 0.01 .
• the catalyst further comprises a multidentate amine ligand as well as a transition metal.
• the reducer must be suitable for reducing the metal of the catalyst so as to make it active in reversibly extracting a halogen from the initiator or from the radical chain in the dormant form and forming a radical able to propagate by adding monomer.
• the reducing agent can be either inorganic or organic, e.g. ascorbic acid, stannous compounds, reducing sugars, mercaptans, alcohols.
• the ARGET-ATRP reaction can be carried out in the presence of solvent and a base. An excess of multidentate amine ligand with respect to the metal of the catalyst increases the reaction speed.
• US 8,933,183 describes an ARGET-ATRP process applied to monomers derived from (meth)acrylic acid that uses a copper based complex catalyst.
• Said catalyst contains 5 ppm to 30 ppm by weight of copper atoms, and a molar quantity less than or equal to 7 mmol % of a multidentate amine as the ligand, wherein said amine is present in molar quantities less than or equal to 150% by moles with respect to the total content of copper atoms.
• the reactant system further contains at least one reducing agent and at least one base.
• the reducing agents include alcohols, aldehydes, phenols and organic acids such as ascorbic acid and salts and esters of ascorbic acid.
• the base is a mono- or poly-amine organic compound or an inorganic compound of lithium, sodium and calcium, including sodium methoxide, potassium ethoxide, hydroxides, carbonates, bicarbonates, phosphates, acetates, oxalates, ascorbates.
• the ARGET-ATRP process for the controlled polymerization of (meth)acrylic monomers can be carried out in a solvent suitable to solubilize ascorbic acid, such as organic or aqueous mixtures that include methanol, ethanol, propanol, dimethylsulfoxide, dimethylformamide, dimethylacetamide, N-methylpyrrolidone.
• a solvent suitable to solubilize ascorbic acid such as organic or aqueous mixtures that include methanol, ethanol, propanol, dimethylsulfoxide, dimethylformamide, dimethylacetamide, N-methylpyrrolidone.
• the resulting (meth)acrylic polymer has a distribution of molecular weights that ranges from 1.1 to 1.8.
• the ATRP synthesis process is suitable for the production of polymers with a controlled, linear, branched structure, with reactive functions.
• the control of the polymerization reaction is regulated by the balance between non-active (dormant) and active (living) forms of the polymer chain, which depends in turn on the oxide-reductive balance of the catalytic system used with a multidentate amine ligand.
• Said ligand is selected based on the monomer and on the halogen present in the reaction system as described in Journal of The American Chemical Society (2008 130(32) 10702-10713).
• the initiator is selected so that it is more reactive than the polymer chain in the non-active form so that the initiation of the polymer chains is promoted with respect to their propagation.
• the vinyl aromatic monomers are less reactive than the (meth)acrylic monomers and require higher temperatures or more effective ligands in shifting the reaction balance from the dormant to the active form.
• the use of difunctional initiators i.e. with two halogens per molecule, allows the control of the reaction to be maintained also in the case of termination by coupling of two radical chains in the active form, as the chain produced maintains two halogenated terminals although having a length provided by the sum of the two reacting chains.
• the linear or branched structure cannot be modified by changing the temperature or concentration of the reactants, but only by inserting, or not, polyfunctional initiators with at least three functions, or polyvinyl monomers with at least two vinyl groups per molecule, or vinyl monomers with halogen groups that can act both as monomers in the propagation of the polymer chain and as initiators of new chains (also known as inimers).
• the ARGET-ATRP known up to now makes the ATRP process cheaper, by reducing up to over twenty times the quantity of catalyst containing transition metal or multidentate amine ligand, necessary for carrying out the reaction without modifying the variety of polymer structures that can be obtained with respect to the ATRP process.
• the Applicant has found a process for the synthesis of vinyl aromatic polymers in which the sequence of monomers in chain and the linear, branched soluble or crosslinked insoluble, structure, with reactive functions or different polarities, can be controlled, which process uses an Atom Transfer Radical Polymerization (ATRP) reaction of vinyl aromatic monomers with Activator ReGenerated by Electron Transfer (ARGET), in the present text indicated as ARGET-ATRP.
• ATRP Atom Transfer Radical Polymerization
• ARGET Electron Transfer
• the structure (linear, branched or crosslinked) of the polymers produced can be obtained without adding branching or crosslinking substances, polyfunctional initiators with at least three functions, polyvinyl monomers or inimers that can provide branched polymer structures, but simply by regulating the reaction temperature and/or the relative quantities of components of the reaction mixture, in particular reactants and solvent pair.
• the subject matter of the present invention is a polymerization process for the synthesis of vinyl aromatic polymers, in which the sequence of monomers in the chain and the linear, branched soluble, or crosslinked insoluble structure, with reactive or different polarity functions, are controlled; said process comprises the step of
• ATRP Polymerization
• ARGET Activator ReGenerated by Electron Transfer
• the reaction being carried out at a temperature comprised between 25°C and 1 10°C in an inert gas atmosphere in the presence of a complex catalyst containing a cupric halide and a multidentate amine ligand, feeding to the reaction an organic initiator having two geminal halogens, an alkali metal (bi)carbonate, a solvent pair of an aliphatic alcohol and an acetic ester of the same aliphatic alcohol and possibly ascorbic acid, provided that no initiator is used with three or more active halogens, or polyvinyl monomers or inimers.
• the advantage of the process according to the present patent application consists of the possibility to produce vinyl aromatic polymers in which the sequence of monomers in chain and the linear, branched soluble, or crosslinked insoluble structure, with reactive functions or different polarities, are controlled, which can be used for producing block polymers, without the use of polyfunctional initiators with 3 or more functions, of polyvinyl monomers and inimers used to obtain branched polymer structures, at contained costs due to the low complex catalyst concentration and the low cost of the other necessary components.
• the process allows the structure of the vinyl aromatic polymer to be controlled in a versatile way by changing the temperature and the composition of the reaction mixture, without introducing expensive reactants.
• the vinyl aromatic monomers are subject to an Atom Transfer Radical Polymerization (ATRP) reaction with an Activator ReGenerated by Electron Transfer (ARGET).
• ATRP Atom Transfer Radical Polymerization
• ARGET Activator ReGenerated by Electron Transfer
• the reaction is carried out in an inert gas atmosphere at a temperature comprised between 25°C and 1 10°C.
• An organic initiator is fed to the reaction having two geminal halogens, an alkali metal (bi)carbonate, a solvent pair of an aliphatic alcohol and an acetic ester of the same aliphatic alcohol and possibly ascorbic acid, provided that initiators with three or more active halogens are not used, or polyvinyl monomers or inimers.
• vinyl aromatic polymers are produced in which the sequence of monomers in chain and the linear, branched soluble, or crosslinked insoluble structure, with reactive functions or different polarity, are obtained by controlling the temperature and concentration of the compounds that form the reaction mixture.
• reaction mixture contains at least one vinyl aromatic monomer, at least one organic initiator with two geminal halogens, at least one catalyst containing a cupric halide and a multidentate amine ligand, alkali metal (bi-)carbonate and a solvent pair of an aliphatic alcohol and of an acetic ester of the same aliphatic alcohol.
• the reaction can be carried out in an inert gas atmosphere at a temperature preferably comprised between 70°C and 1 10°C, more preferably comprised between 80°C and 1 10°C, even more preferably comprised between 90°C and 1 10°C, even more preferably between 90°C and 100°C.
• ascorbic acid is present at temperatures less than or equal to 100°C (soluble) branched polymer structures can be obtained and at temperatures comprised between 60°C and 70°C, if the solvent pair is comprised of ethyl acetate and ethanol, (insoluble) crosslinked polymer structures can be obtained.
• organic initiators with only one halogen instead of two geminal halogens, although in the presence of all the other components of the reaction mixture listed for the formation of branched or crosslinked polymer, at temperatures comprised between 25°C and 1 10°C, only polymers with a linear structure are obtained.
• the vinyl aromatic monomers that can be used in the process according to the present patent application have general formula (I):
• R is a hydrogen or a methyl group
• n is zero or an integer from 1 to 3
• Y is a halogen selected from chlorine or bromine, or Y is an alkyl group or an alkoxy group having 1 to 3 carbon atoms.
• the preferred vinyl aromatic monomers having formula (I) are selected from styrene, a- methyl-styrene, vinyltoluene isomers, ethylstyrene isomers, propylstyrene isomers, chlorostyrene isomers, bromostyrene isomers, methoxystyrene isomers, acetoxystyrene isomers, and mixtures thereof. More preferably said vinyl aromatic monomers can be selected from styrene and mixtures of styrene and a-methyl-styrene.
• the initiators with two geminal halogens that can be used in the process described and claimed in the present patent application have formula X 2 -C-(R1 )R2 where X is a halogen selected among F, Cl, Br or I; R1 is H in the event in which R2 is an aromatic group, preferably selected from phenyl or substituted phenyl, or R1 is an aliphatic alkyl group with one to 20 carbon atoms, preferably 2 to 15 carbon atoms, more preferably 2 to 10 carbon atoms, with a linear or branched structure if R2 is an alkyl ester comprising a carboxyl group with a linear or branched alkyl containing 1 to 30 carbon atoms, preferably 1 to 20 carbon atoms, more preferably 1 to 10 carbon atoms.
• X is preferably selected from chlorine and bromine, even more preferably it is chlorine which is more suitable when protic solvents are used that have a labile hydrogen atom that can be yielded as an H + ion; protic solvents that can be used can be selected from alcohols, diols, polyols, fluoroalcohols or carboxylic acids; methanol and ethanol are more preferred.
• di-halogenated initiators must have both halogens with reactivity greater than or equal to the same terminal halogens of the vinyl aromatic chains propagating in the inactive form. If one of the two halogens of the initiator were more stable in the initial form with respect to the vinyl aromatic chain with the terminal halogen, the polymer chain would continue to grow and a new chain would not initiate.
• Non- geminal, symmetric di-functional initiators have the same reactivity and therefore if one halogen is active then the other is also active.
• the second halogen maintains reactivity greater than or equal to the first halogen that reacted and became the end of the vinyl aromatic chain originated therefrom, hence the dual function and the growth of two vinyl aromatic chains by initiator molecule is guaranteed in the ideal case of a perfectly controlled reaction, without termination reactions by disproportion and transfer that imply the removal of chain end halogens.
• Preferred initiators with two geminal halogens are selected from benzal halides, ethyl 2-bromo-iso-butyrate, (di-chloromethyl) benzene, CuC , methyl 2,2-dichlorobutanoate, ethyl 2-chloroisobutanoate, ethyl 2,2-di-chloro- propanoate, methyl 2,2-di-chloro-butyrate.
• Preferred initiators are ethyl 2,2-di-chloro- propanoate and benzal chloride.
• the solvent that can be used in the process described and claimed in the present patent application is a mixture that contains an acetic ester of an aliphatic alcohol and the aliphatic alcohol itself.
• Aliphatic alcohols that can be used in the process described and claimed can be selected from methanol, ethanol, propanol, iso-propanol, ter-butanol. Methanol, ethanol, propanol and iso-propanol are also reducing substances towards the oxidized form of the catalyst.
• Acetic esters of aliphatic alcohols that can be used in the process described and claimed can be selected from methyl acetate, ethyl acetate and propyl acetate, iso-propyl acetate, tert-butyl acetate.
• Preferred mixtures of solvent between acetic ester of an aliphatic alcohol and the aliphatic alcohol itself are selected from ethyl acetate and ethyl alcohol, methyl acetate and methanol, isopropyl acetate and iso-propanol, tert-butyl acetate and tert-butanol.
• the most preferred solvent mixture also due to its high environmental compatibility may be the mixture that contains ethyl acetate and ethyl alcohol.
• the complex catalyst that is used in the process described and claimed contains a cupric halide and a multidentate amine ligand.
• the halogen of the cupric halide is preferably the same halogen present in the initiator.
• the multidentate amine ligand may be present in equimolar or excess quantities of ligand up to 200% by moles with respect to the moles of cupric halide that correspond to copper gram-atoms.
• molar concentrations of copper dihalide are preferably used, comprised between 1/5 and 1/20, preferably comprised between 1/10 and 1/20, more preferably comprised between 1/15 and 1/20, with respect to the molar concentration of molecules of initiator.
• Concentrations of copper atoms expressed in gram-atoms per liter of reaction mixture less than 1/20 with respect to the molar concentration of molecules of initiator do not guarantee optimal control of the reaction, in particular for initiator quantities less than 1 % by moles with respect to the vinyl aromatic monomer in the initial reaction mixture.
• the concentration variation of the catalyst with respect to that of the organic initiator with two geminal halogens, of the solvent system of the vinyl aromatic monomer, of the carbonate and of the reducing compound does not modify the structure of the polymer that is obtained under the same reaction conditions. If insoluble polymer is obtained with 1/5 catalyst with respect to the initiator, it is also obtained with 1/20 under all the same reaction conditions in terms of concentrations of different components, temperature and reaction time.
• the halogen that is used in the copper halide is preferably the same as that of the initiator, preferably it is selected from chlorine or bromine; chlorine is most preferred.
• the multidentate amine ligand based on its structure, allows the efficacy of the catalyst to be regulated in the balance between the non-active form of the vinyl aromatic polymer chain, that terminates with a halogen atom, and the active radical form, as described in Journal of the American Chemical Society (2008 130(32) 10702-10713).
• a more active ligand increases the concentration of free radicals and allows a greater reaction speed to be obtained, but reduces the control of the structure as a high concentration of reactive radicals promotes both the propagation of the chains and their termination and transfer to monomer.
• the activity of the ligand in extracting a halogen from the initiator or from the dormant chain increases when passing from the multidentate amine 2,2’-bipyridine (bpy), to PentaMethyIDiEthyleneTriAmine (PMDETA), to Tris[(2-Pyridyl)methyl]-Amine(TPMA), to 5,5,7, 12,12, 14-hexaMethyl-1 ,4,8,1 1 -tetra-azaCyclo-tetradecane (Me6Cyclam) and, with the same initiator and monomer, bromine is more easily extractable from chlorine.
• Multidentate amines selected from 2,2’-bipyridine (bpy), PentaMethyIDiEthyleneTriAmine (PMDETA), Tris[(2-Pyridyl)methyl]-Amine(TPMA) and 5,5,7,12,12, 14-hexaMethyl- 1 ,4,8,1 1 -tetra-azaCyclo-tetradecane (Me6Cyclam) are preferred.
• an alkali metal (bi)carbonate must be used without which the polymerization reaction of vinyl aromatic monomers does not take place.
• This compound is usually used anhydrous and dispersed in the form of powder with dimensions less than or equal to 500 micron in the reaction mixture.
• the (bi)carbonates of alkali metals selected from Li, Na, K, Rb, Cs, Fr, Be, Mg, Ca, Sr, Ba and Ra are preferred; those of sodium and potassium are more preferred; the most preferred as it is widespread and easy to find is that of sodium.
• Reducing compounds may possibly be added to the reaction mixture at the start of or during the polymerization reaction, selected from ascorbic acid or an alkali metal salt of ascorbic acid, organic tin compounds such as tin 2-ethylhexaonoate, organic acids selected from citric acid, oxalic acid, salts and esters of ascorbic acid, organic substances selected from aldehydes or phenols, such as tert-butylcatechol (used as an antioxidant in the storage of vinyl aromatic monomers), tin(ll) 2-ethylhexaonoate and tocopherol.
• organic tin compounds such as tin 2-ethylhexaonoate
• organic acids selected from citric acid, oxalic acid, salts and esters of ascorbic acid
• organic substances selected from aldehydes or phenols such as tert-butylcatechol (used as an antioxidant in the storage of vinyl aromatic monomers), tin(ll) 2-ethyl
• Further reducing agents used in the process described and claimed may be alcohol present in large excess with respect to copper(ll) atoms in the solvent pair acetic ester of aliphatic alcohol and aliphatic alcohol, and the multidentate amine ligand.
• the reducing compounds may be present in lower molar quantities than the (bi)carbonate salt, preferably less than or equal to 1 mole of reducing agent per 2 moles of
• vinyl aromatic polymers can be obtained with a branched soluble, linear structure and, if the solvent pair contains ethanol, crosslinked insoluble, without using tri- or poly-functional initiators or divinyl monomers.
• the controlled polymerization reaction may also be carried out with other reducing agents, but only in the presence of ascorbic acid the formation of branched soluble polymer is observed and in the temperature range between 60°C and 70°C insoluble polymer is formed if the solvent pair is comprised of ethyl acetate and ethanol.
• the inorganic base comprising alkali metal (bi)carbonate is essential for the reaction to take place. Also in the presence of other reducing agents, as well as the alcohol of the solvent system, without alkali metal (bi)carbonate the polymerization of the vinyl aromatic monomer does not take place.
• the function of the inorganic (bi)carbonate base is that of neutralizing any acid present in the reaction mixture and shifting the balance in favor of the formation of active radical chains very effectively. Therefore, the (bi)carbonate is dosed in the minimum quantity necessary to obtain a sufficiently high reaction speed, but not such as to make the reaction uncontrolled.
• the (bi)carbonate is not soluble in the reaction mixture and is active on the surface therefore it is preferable to use sodium or potassium (bi)carbonate with a mean diameter less than or equal to 500 pm and preferably less than or equal to 200 pm. Due to its low cost and wide availability, the preferred basic salt is sodium carbonate.
• a reducing agent may be the alcohol present in large excess with respect to the copper(ll) atoms in the solvent pair acetic ester of aliphatic alcohol and aliphatic alcohol.
• the multidentate amine ligand can also be a reducing agent, but given its high cost it is worth using it in minimum concentrations, in a 1 to 1 molar ratio with the copper atoms.
• the polymerization reaction can be performed at a temperature comprised between 25°C and 1 10°C.
• the polymerization reaction can be carried out at atmospheric or super- atmospheric pressure up to 20 bar on the basis of the reaction and boiling temperature of the reaction mixture in which the solvent mixture is the most volatile component.
• vinyl aromatic monomer styrene (St) stabilized with 10 parts per million by weight of tert-butylcatechol (TBC) in an air atmosphere (made by Versalis S.p.A.), solvent and reducing systems: ethyl acetate (AcOEt), methyl acetate (AcOMet), iso propyl acetate (AcOiPr), ter-butyl acetate (AcOtBu), methanol (Met-OH), ethanol (Et-OH), iso-propanol (i-Pr-OH), ter-butanol (tBu-OH), di-chloromethane (Merck Sigma-Aldrich),
• inorganic bases sodium (bi)carbonate anhydrous (Carlo Erba), reducing agents: ascorbic acid (AA), tert-butylcatechol (TBC), tin(ll) 2- ethylhexanoate (Sn(oct)2) (Merck Sigma-Aldrich),
• ligands tris(2-pyridylmethyl)amine (TPMA),N,N,N’,N”,N”- pentamethyldiethylenetriamine (PMDETA) (Merck Sigma-Aldrich),
• cupric halide ethyl 2-bromoisobutyrate (EBiB), (di- cloromethyl)benzene (CI2TOL), CuC (Merck Sigma-Aldrich),
• DCPE Ethyl 2,2-dichloropropanoate
• DCBM methyl 2,2-dichlorobutanoate
• ECiB ethyl 2- chloroisobutanoate
• the reaction chamber filled with tert-butyl ammonium chloride (TBAC, 2.7 g, 9.6 mmol) and butanoyl chloride (100 ml, 0.955 mol), is heated to 100°C while O2 is insufflated into the solution (40-50 ml/min) and left to bubble.
• TBAC tert-butyl ammonium chloride
• butanoyl chloride 100 ml, 0.955 mol
• the reaction mixture is heated to 120°C then remaining at this temperature for a total of 1 1 hours and 30 minutes; finally it was heated to 125°C and such temperature was maintained up to a total of 13 hours.
• the raw product is transferred into a one-necked flask, where 1 -hexadecene is added to remove any residues of CI2.
• the reaction is repeated a second time and the raw product is distilled to separate the 2,2-dichloro butanoyl chloride (yield « 94%).
• the reaction intermediate is dissolved in 100 ml of methanol and then heated under reflux for 4 h.
• the product is vacuum distilled and analyzed through NMR (purity > 99%).
• the organic phase is isolated with a separator funnel and anhydrified on a column containing Na2CC>3 anhydrous.
• the eluate of two reactions is collected in a 500 ml. flask, AIBN (Merck, Sigma-Adrich, 1 g) is added and it is refluxed for 18 hours to polymerize the ethyl methacrylate, which is formed parallel to the ECiB. Then a first distillation is performed to recover the ester from the mass of
• a Schlenk reactor was used as the reaction vessel (25 ml. useful reaction volume, internal diameter 2.5 cm with oval-shaped magnetic anchor stirrer 2 cm long and with diameter 1 cm), which is a piece of glass suitable for performing reactions in a controlled atmosphere (argon or nitrogen).
• the equipment used is provided with a threaded cap, for transporting the reactants, and a needle valve, to be connected with the gas distributor.
• This configuration of the Schlenk reactor is suitable for carrying out reactions under slight pressure, with solvents that have lower boiling points than the reaction temperature.
• the threaded cap is perforated and provided with a gasket with a teflon-coated side that can also operate as a rupture disc, if the internal pressure is excessive.
• the solid reactants are inserted first, then the atmosphere is changed with at least three vacuum/inert gas cycles (indicatively 3 minutes’ of vacuum, while for the inert gas the period is defined by the reappearance of bubbling from the mercury valve).
• the liquid reactants can be inserted (or the solutions of solid reactants) and the solvents, either with a syringe pipette, by opening the Schlenk reactor and letting the inert gas flow freely, or with a syringe, provided with a metal needle, perforating the baffle.
• this particular reactor is coupled to a gas distributor, a device in which a vacuum line and an inert gas are integrated, and can alternatively be connected to a single outlet, through the activation of a tap.
• the vacuum pump is connected directly to the distributor, whereas the direct junction between the distributor and the inert gas cylinder is not possible. It is dispensed from the cylinder through a double-stage pressure reducer, the second of which is sufficiently fine to be able to be easily regulated, and from there it enters into a device adapted to fix the pressure of the gas in line. This is obtained through a mercury bubbler, where the height of the Hg column determines the operating pressure, after exceeding which the bubbling of the gas towards the outside begins.
• the reaction mixture contained in the Schlenk is thermostated in an oil (or water) bath at the temperatures and for the times fixed with stirring at 400 rpm using a magnetic anchor stirrer.
• the Schlenk reactor is then cooled in air for 15 minutes and the contents thereof subsequently diluted with CH2CI2 (typically 20 ml. or more).
• CH2CI2 typically 20 ml. or more
• the polystyrene is precipitated, dripping the dichloromethane solution into plenty of methanol (250 ml_).
• a small quantity (2 ml. circa) of HCI 10% aq. can be added (weight/V). It is left to decant for 2-3 h and filtered on a filtering funnel P4 (75 ml_), previously weighed.
• the molecular mass distribution of polymers soluble in THF obtained was performed through liquid gel permeation chromatography (GPC) with a refractive index (Rl) detector, viscometer (VISCO) and Multi Angle Laser Light Scattering (MALLS). Polymers that with a MALLS detector display a weight average molecular mass (Mw) 20% greater with respect to the same Mw obtained with a Rl detector are considered branched.
• the GPC equipment comprises:
• Viscotek T50A viscometer detector calibrated with Viscotek polydisperse standard, with intrinsic declared viscosity.
• the samples are injected at the concentration of 1 mg/ml.
• the universal calibration curve is constructed by injecting 20 standard of monodispersed polystyrene, with molecular weight Mp comprised between 2170 Da and 4340000 Da, recording for every molecular weight the intrinsic viscosity and the elution volume.
• Empower2 Waters
• Omnisec Omnisec v.4.6.1 software
• the examples and tables show the formulations, the temperature (T) and the reaction time (hours), the polymerized styrene fraction with respect to the initial mass inserted (X), the number average molecular mass (Mn) measured with Rl detector, Mw/Mn measured with Rl detector, the linear or branched or crosslinked structure obtained, the n.d. index which indicates a measurement that is not determinable.
• the conversion (X) increases with the temperature (T) and the reaction time (t). From 90°C to 1 10°C linear polymers are obtained, but at 80°C and at 43°C branched polymer structures are obtained and at 60°C a crosslinked polymer is obtained
• Comparative example 10 all the components are present for carrying out ARGET- ATRP polymerization, such as Cu(ll), multidentate amine ligand, TPMA, in molar concentration equal to that of the copper atoms, ethanol and ascorbic acid as reducing agents, but, in the absence of Na2CC>3, the polymerization reaction does not take place.
• Example 1 even with ethanol only as the reducing agent, without Na2CC>3, the polymerization reaction does not take place.
• Example 12 even with ascorbic acid as the reducing agent in molar concentration equal to that of Na2CC>3, the polymerization reaction does not take place.
• Example 13 without ascorbic acid, in the presence of Na 2 C0 3 , the polymerization reaction takes place and, also with high styrene conversions (98%), even with Mw/Mn greater than 2, branched polymer is not obtained.
• linear polymers are obtained in Example 17-20, in analogous reaction conditions to examples 5-8, but without ascorbic acid.
• Example 21 with 0.25 moles of Na 2 C0 3 with respect to 100 moles of styrene, a linear polymer is produced with Mn equal to the theoretical one, which would be obtained with ideal“controlled-living” polymerization in which a molecule of initiator initiates two polymer chains.
• the ligand PMDETA is less effective than TPMA in the formation of the active polymer species and the conversions are lower with the same other reaction conditions.
• Example 45 with 0.5 ml. of Et-OH and the ratio AcOEt/Et-OH 7/1 by volume there is a lower reaction speed and crosslinking is not reached (no insoluble polymer is formed) as in Example 46 by doubling the quantities of solvent, in the same AcOEt/Et-OH ratio as Example 42.
• Example 48 By increasing the ratio between the initiator and ascorbic acid, [DCPE]:[AA] from 1.06:0.5 to 2.12:0.5 in Example 48 with respect to Example 47, with the same amounts of the other components, volumes of solvent mixture, temperature (70°C) and reaction time (18 hours), no insoluble polymer is formed, but linear polymer with slightly lower conversion.
• Example 50 bringing back the [DCPE]:[AA] ratio to 2.12:1 , as in example 47 (where [DCPE]:[AA] at 1.06:0.5) insoluble polymer is obtained with complete styrene conversion.
• the concentration of catalyst is indifferent in the formation of insoluble polymer.
• Example 54 by halving the quantity of DCPE initiator with respect to Example 53, highly branched, but not insoluble polymer, is obtained.
• Example 55 by doubling the quantity of styrene with respect to Example 53, branched, soluble polymer is obtained again, but the solution is less viscous than Example 54.
• Example 53 With the same other conditions, in Example 53, with 0.5 %mol of AA and 1 .5 %mol of Na2CC>3, with respect to [St], insoluble polymer was obtained. Also in Example 58, by increasing AA to 0.75 %mol with respect to [St] insoluble polymer is obtained. In Example 59, by reducing Na2CC>3 to 1 .0 %mol with respect to [St] branched polymer is obtained and in Examples 56 and 57 by reducing AA/Na2CC>3 to 0.25/0.75 and 0.25/1 .5 linear polymer is obtained.
• Example 42 by carrying out the reaction at 60°C, for 13 hours, with 3 ml. of styrene (26.1 mmol), 3 ml. of AcOEt and 1 ml. of Et-OH, 1 .06 %mol of DCPE initiator, 0.05 %mol of CuC -TPMA catalyst and AA/Na2CC>3 content 0.5/1.5 %mol/%mol with respect to [St], insoluble (crosslinked) polymer was obtained with X (styrene conversion) of about 74%. Under the same reaction and formulation conditions (reaction time 15 hours, instead of 13 hours) by substituting 3.25 ml. of ethyl acrylate (EA, 26.1 mmol) with the 3 ml. of styrene, linear polymer is obtained as reported in Table 14.
• EA ethyl acrylate

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