Controlled Radical Polymerization at High Conversion: Bulk ICAR ATRP of Methyl Methacrylate

Methyl methacrylate (MMA) was polymerized in bulk via atom transfer radical polymerization (ATRP) with azobis(isobutyronitrile) (AIBN) and tert-butyl peroxybenzoate (TBPB) as initiator for continuous activator regeneration (ICAR). The ATRP was first carried out up to high conversion at 70 °C. When the system reached its glass state at about 94%, the polymerization temperature was elevated to 120 °C to maximize the conversion. Livingness of the ICAR ATRP process and control of polymer molecular weight at high conversion were carefully examined to elucidate the mechanisms of diffusion-controlled reactions. The “gel effect” started at about 50% conversion, and it was accompanied by molecular weight distribution broadening. A dramatic increase in polydispersity was observed at above 90% conversion. The loss of control over molecular weight was caused by diffusion-controlled deactivation, which could be reduced to some extent by increasing deactivator concentration. However, despite the loss of control at high conversion, livingness of the system did not suffer, owing to diffusion-controlled termination. The polymer chains collected at very high conversion could be easily extended with high efficiency.