Living radical polymerisation in heterogeneous conditions—suspension polymerisation

Transition metal mediated living radical polymerisation of butyl methacrylate has been demonstrated with a copper(I) halide N-alkyl-2-pyridylmethanimine ligands based catalyst. Optimum conditions were found to be with copper(I) chloride and N-octyl-2-pyridylmethanimine catalyst at 65 °C where conversions of 85% were achieved with polymers of M_n = 8900 g mol⁻¹ (theoretical = 8400 g mol⁻¹) and PDI = 1.23. Both non-ionic and ionic surfactants were employed which were also made by living radical polymerisation. The non-ionic surfactant was a block copolymer of PMMA from a polyethyleneglycol macroinitiator (total M_n = 7600 g mol⁻¹, PDI = 1.20) and the ionic surfactant PDMEAMA-PMMA (total M_n = 8000 g mol⁻¹, PDI = 1.21) with the PDMEAMA block quaternized with MeI (13.8%, 28.4%, 47.7% and 100%). A range of ligands were employed in the suspension polymerisation by varying the alkyl group on the ligand increasing the hydrophobicity (alkyl = propyl (PrMI), pentyl (PMI), octyl (OMI), dodecyl (DMI) and octadecyl (ODMI)). The more hydrophobic ligands were found to be more effective due to lower partitioning into the aqueous phase. Block copolymers of P(EMA)-P(BMA) and P(MMA)-P(BMA) were prepared by first preparing macroinitiators via living radical polymerisation (M_n = 1600 g mol⁻¹ (PDI = 1.23) for P(EMA) and M_n = 1500 g mol⁻¹ (PDI = 1.22) for P(MMA)) and using them for initiation of BMA in suspension polymerisation. Block copolymers had M_n between 12,800 and 13,700 g mol⁻¹ with PDI between 1.33 and 1.54. Block copolymer growth showed excellent linear first order kinetics wrt monomer and demonstrated characteristics expected of a living radical polymerisation. Particle sizes were measured by SEM and DLS with good agreement (1.4-2.8 μm) and SEM showed spherical particles were formed.