Targeting Copolymer Composition Distribution via Model-Based Monomer Feeding Policy in Semibatch RAFT Mini-Emulsion Copolymerization of Styrene and Butyl Acrylate

Copolymer composition distribution (CCD) is an important parameter of chain microstructure that has significant impact on the material properties of polymer products. Controlled/living radical polymerization (CLRP) has provided a great opportunity in producing polymers with predesigned CCDs through a model-based monomer feeding policy (MMFP) in homogeneous systems. In this work, the MMFP has been expanded to heterogeneous systems. Reversible addition–fragmentation transfer (RAFT) mini-emulsion polymerizations of styrene (St) and butyl acrylate (BA) were carried out with 3-benzyltrithiocarbonyl propionic acid (BCPA) used as a RAFT agent. A kinetic model was developed and correlated to the batch St/BA RAFT mini-emulsion experimental data for parameter estimation. The MMFP was then developed by combining the kinetic model with a semibatch reactor model and applied to the semibatch St/BA RAFT mini-emulsion copolymerization for the synthesis of targeted CCDs. The model agreed well with the polymerization kinetics. A series of St/BA copolymers with predesigned CCDs were successfully synthesized.