CN1276930C - 制备聚合物纳米颗粒的高固体分方法 - Google Patents
制备聚合物纳米颗粒的高固体分方法 Download PDFInfo
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- CN1276930C CN1276930C CNB2004100447740A CN200410044774A CN1276930C CN 1276930 C CN1276930 C CN 1276930C CN B2004100447740 A CNB2004100447740 A CN B2004100447740A CN 200410044774 A CN200410044774 A CN 200410044774A CN 1276930 C CN1276930 C CN 1276930C
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- 229910052723 transition metal Inorganic materials 0.000 description 1
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- KEROTHRUZYBWCY-UHFFFAOYSA-N tridecyl 2-methylprop-2-enoate Chemical compound CCCCCCCCCCCCCOC(=O)C(C)=C KEROTHRUZYBWCY-UHFFFAOYSA-N 0.000 description 1
- PKRKCDBTXBGLKV-UHFFFAOYSA-N tris(ethenyl)-methylsilane Chemical compound C=C[Si](C)(C=C)C=C PKRKCDBTXBGLKV-UHFFFAOYSA-N 0.000 description 1
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Abstract
本发明涉及制备直径为1-200nm的交联聚合物纳米颗粒的非乳液高固体分方法。
Description
本发明的背景
在过去的几年里,聚合物纳米颗粒已引起了越来越多的关注。与普通化合物相比,聚合物纳米颗粒具有改进的机械强度,运输性能的更大控制,材料性能可调节性和尺寸稳定性。因为这些性能,聚合物纳米颗粒可用于各种各样的应用,如催化,涂料,作为控释元件的药物,生物结构填料,电子和聚合物复合材料。
目前认为,要想成功地生产聚合物纳米颗粒,反应剂和最终产物必须在反应介质内充分分散。开发用于生产聚合物纳米颗粒的方法包括溶液聚合和分散体聚合。然而,目前的溶液和分散体方法仅能够生产低含固量的聚合物纳米颗粒。还能够通过使用稀释条件和/或大用量的分散剂如表面活性剂用乳液聚合来生产高含固量的小颗粒,通常具有大于50纳米的平均粒度。高用量的表面活性剂和可聚合表面活性剂的使用在本领域中公知是在水乳液聚合中生产聚合纳米颗粒的有效方式。然而,遗憾的是,使用高用量的表面活性剂产生了性能问题。例如,在涂料应用中,这些问题包括降低的耐水牢度和耐擦洗性。
人们已经尝试通过避开使用表面活性剂来解决这些问题。已经使用无表面活性剂的稀非水溶液方法来生产聚合物纳米颗粒。例如在U.S.专利No.5,863,996中,公开了用于生产具有5,000到20,000,000的重均分子量的交联聚合物的溶液聚合方法。在该专利中公开用于制备交联聚合物溶胶的任何方法的最高固体百分数(在发生胶化之前分离)是20%。
此外,U.S.专利申请2003/0008989A1描述了通过利用无表面活性剂的溶液聚合方法制备交联聚合物纳米颗粒来解决该问题的尝试。然而,在高于25%固体分下进行的实验导致了大粒凝胶和凝胶的形成,没有获得纳米颗粒。
这些方法虽然已消除了表面活性剂,但仍然缺乏生产高固体分聚合物纳米颗粒的方法。高固体分的生产方法是所希望的,因为节约了时间和金钱,使高固体分方法成为更有活力的工业方法。本发明的方法解决了现有技术没能解决的问题。本发明的方法生产出了固体分等于或高于30wt%的聚合物纳米颗粒,没有胶化或收率低的问题。
本发明涉及制备聚合物纳米颗粒的方法,包括将反应剂加入到容器中和让所述反应剂反应,以形成交联聚合物纳米颗粒,其中所述聚合物纳米颗粒具有1-200nm的平均粒径和其中该方法是非乳液方法和其中该方法获得了等于或高于30wt%的聚合物纳米颗粒的固含量。
本发明的一个方面是该方法是非乳液方法。这里使用的术语“乳液”是指两种或多种不混溶的液体通过少量的称为乳化剂的物质保持悬浮的稳定混合物。所有乳液均包括连续相和分散相。例如,在乳液聚合中,水是连续相,单体是分散相,以及常常使用表面活性剂作为乳化剂。
通过本发明的方法形成的聚合物纳米颗粒能够进行交联。交联在聚合过程中通过使用多官能反应剂或通过其中聚合物链由官能团连接在一起的后反应来完成。例如,交联剂能够以1-100wt%的量添加,又例如,交联剂能够以5-80wt%的量添加,还例如,交联剂能够以10-50wt%的量添加。
粒度能够通过测量平均粒径来测定。除了平均粒径以外,还能够测量粒径分布。用本发明的方法形成的聚合物纳米颗粒的平均粒径的实例为1-200nm,另一实例为1-100nm,又一个实例是1-50nm。粒径分布的一个实例是1-200nm,另一个实例是2-100nm,又一个实例是2-50nm。平均粒径和粒径分布的控制能够通过诸如选择溶剂,选择引发剂,总固体含量,引发剂量,反应剂的种类和量以及反应条件之类的方法来获得。测定平均粒径和粒径分布的技术能够使用包括、但不限于标准动态光散射,小角中子散射NMR漫射,X射线散射和胶体相色谱法的技术来测定。
聚合物纳米颗粒的凝胶渗透色谱法(GPC)洗脱倍数从而提供了平均粒径的指示。聚合物纳米颗粒的粒度能够通过比较聚合物纳米颗粒与具有已知分子量和水力半径的聚苯乙烯标准来测定。所使用的凝胶渗透色谱技术应用含有10微米PL凝胶的柱子比较交联聚合物纳米颗粒的洗脱倍数与已知分子量和水力半径的聚苯乙烯标准的洗脱倍数。
此外,本发明的方法可以通过以诸如连续、分步、定时或脉冲添加之类的方式添加反应剂来进行。这种进料的一个实例是脉冲添加,其中将分多次添加的反应剂加入到反应容器内,在各次添加之间相隔其中不进给反应剂的一段时间间隔。在各次添加之间的时间间隔可以是相同或不同的。分隔等份反应剂各次添加的时间间隔的实例是1秒钟或1秒钟以上,所述时间间隔的另一实例可以是1秒钟到8小时,所述时间间隔的又一个实例可以是30秒钟到8小时。还有,反应剂可以作为两个或多个等份部分添加。反应剂添加的另一个实例可以是添加至少三个等份部分,又一个实例可以是添加四个或四个以上的等份部分。虽然不受理论制约,但据信,通过以脉冲添加方法添加反应剂,聚合物纳米颗粒至少部分在反应混合物中形成,并且在添加下一个等份部分之前分散,这样可以使固含量增加,而不形成大粒凝胶。
本发明的方法的总反应时间例如能够是2秒钟到24小时,作为另一个实例,本发明的方法的总反应时间能够是1小时到20小时,作为又一个实例,本发明的方法的总反应时间能够是3小时到15小时。
通过实施本发明获得的聚合物纳米颗粒固含量例如等于或高于30wt%,作为另一个实例,该固含量能够大于或等于35wt%,大于或等于40wt%,大于或等于45wt%,大于或等于50wt%,大于或等于55wt%,大于或等于60wt%,在还一个实例中,该固含量大于或等于65wt%。固体重量百分数能够这样来测定:将最终聚合物纳米颗粒溶液的称重样品放置在固体天平上,将样品加热到160℃,直到再也没有挥发物放出为止,再测量失去的挥发性非固体材料的重量来测定由本发明的方法生产的最终聚合物纳米颗粒溶液的固含量。初始重量减去损失重量,再除以初始重量和乘以100将等于由本发明的方法生产的聚合物纳米颗粒溶液的wt%固含量。
另外,固体wt%可以使用类似技术在添加各等份反应剂之后来测定。例如,在第一次添加之后测定的固体wt%可以高达5wt%,高达10wt%,高达15wt%,高达20wt%或20wt%以上。第二等份部分的添加将固体wt%增加到高达总共10wt%,或15wt%,20wt%,30wt%或30wt%以上。后续等份部分继续增加固含量,直到获得最终需要的固含量。
多个等份部分,脉冲添加和反应时间的组合的实例可以如下:经15分钟的时间将第一等份部分的反应剂加入到反应容器内,在30分钟的停顿时间之后,经15分钟的时间添加第二等份部分,在30分钟的停顿时间之后,经15分钟的时间添加第三等份部分,随后是30分钟的停顿时间。添加反应剂和停顿的该方法持续到获得等于或高于30wt%交联聚合物纳米颗粒的所需固含量为止。
本发明的方法的另一个实例如下所示:经60分钟的时间将第一等份部分的反应剂加入到反应容器内,在10分钟的停顿时间之后,经30分钟的时间添加第二等份部分,随后是30分钟的停顿时间,之后经15分钟添加第三等份部分,随后是30分钟的停顿时间。添加反应剂和停顿的该方法持续到获得等于或高于30wt%交联聚合物纳米颗粒的所需固含量为止。
本发明的方法的又一个实例如下所示:经10分钟的时间将第一等份部分的反应剂加入到反应容器内,在30分钟的停顿时间之后,经10分钟的时间添加第二等份部分,随后是30分钟的停顿时间,之后经10分钟的时间添加第三等份部分,再之后是30分钟的停顿时间。添加反应剂和停顿的该方法持续到获得等于或高于30wt%交联聚合物纳米颗粒的所需固含量为止。
在反应剂添加过程中,反应温度一般保持恒定,但是可以改变反应温度。在添加完反应剂混合物之后,能够将其它反应剂加入到反应中和/或能够使用停留时间。示例性反应温度范围是-30℃到150℃,另一示例性范围是0-120℃,又一个示例性范围为30-90℃。
本发明的方法能够通过溶液聚合,分散体聚合,悬浮聚合和沉淀聚合来进行。
所谓“溶液聚合”在本文中是指在用于聚合物的溶剂中的聚合。所谓“用于聚合物的溶剂”在本文中是指具有与聚合物纳米颗粒基本相似的聚合单体单元的线性无规聚合物(共聚物)可溶于该溶剂中。还能够使用如在本文公开的溶解度参数分析来选择适合的溶剂或溶剂混合物。
用本发明的方法生产的聚合物纳米颗粒能够在水性或非水溶剂体系和它们的组合中制备。非限制性溶剂的例子包括:烃类,如链烷烃,卤代烃类,如氯化、氟化和溴化烃类,芳族烃类,醚类,酮类,酯类,水,醇类和它们的混合物。尤其适合的溶剂包括十二烷,癸烷,1,3,5-三甲苯,二甲苯类,二苯醚,γ-丁内酯,乙酸乙酯,乳酸乙酯,丙二醇单甲基醚乙酸酯,己内酯,2-庚酮,甲基异丁基酮,二异丁基酮,丙二醇单甲醚,和烷基醇,如癸醇,叔丁醇,和异丙醇(“IPA”)。
通过本发明生产的聚合物纳米颗粒能够通过分散体聚合来制备。所谓“分散体聚合”在本文中是指在使得所生产的聚合物不溶,但通过静电或位阻稳定作用保持为均相的溶剂中的聚合。
通过本发明生产的聚合物纳米颗粒能够通过悬浮聚合来制备。所谓“悬浮液聚合”在本文中是指在使得所生产的聚合物不溶,但通过静电或位阻稳定作用保持为稳定的双相体系的溶剂中的聚合。
通过本发明生产的聚合物纳米颗粒能够通过沉淀聚合来制备。所谓“沉淀聚合”在本文中是指在使得所生产的聚合物不溶的溶剂中的聚合。
通过本发明的方法制备的聚合物纳米颗粒能够使用任何反应性材料,包括例如单体、可交联聚合物或交联聚合物来制备。
可用于实施本发明的反应剂能够是有机材料如单体(甲基)丙烯酸烷基酯,脂环族(甲基)丙烯酸酯,(甲基)丙烯酰胺,乙酸乙烯酯,(甲基)丙烯酸链烯基酯,(甲基)丙烯酸芳基酯,(甲基)丙烯酸烷芳基酯,含胺的(甲基)丙烯酸酯,含磷的(甲基)丙烯酸酯,含硫的(甲基)丙烯酸酯,乙烯基芳族单体,(甲基)丙烯酸,和取代的烯类单体。示例性(甲基)丙烯酸烷基酯,如甲基丙烯酸甲酯(“MMA”),丙烯酸甲酯,丙烯酸乙酯,甲基丙烯酸丙酯,甲基丙烯酸丁酯(“BMA”),丙烯酸丁酯(“BA”),IBMA,甲基丙烯酸己酯,甲基丙烯酸环己酯,丙烯酸环己酯,丙烯酸2-乙基己酯(“EHA”),甲基丙烯酸2-乙基己酯,甲基丙烯酸辛酯,甲基丙烯酸癸酯,甲基丙烯酸异癸酯,甲基丙烯酸十一烷基酯,甲基丙烯酸十二烷基酯,甲基丙烯酸十三烷基酯,甲基丙烯酸十四烷基酯,甲基丙烯酸十五烷基酯,甲基丙烯酸十六烷基酯,甲基丙烯酸十七烷基酯,甲基丙烯酸十八烷基酯,甲基丙烯酸十九烷基酯,甲基丙烯酸二十级烷基酯,甲基丙烯酸二十烷基酯,和它们的混合物可用于制备聚合物纳米颗粒。
用于制备含有酸官能化单体的聚合物纳米颗粒的有用的(甲基)丙烯酸取代烷基酯单体可以包括在烷基中具有一个或多个羟基的那些,如具有选自(C2-C6)烷基,支化和非支化烷基中的取代烷基的(甲基)丙烯酸羟烷基酯单体。同样,在使用含羟基的单体或含乙酰乙酰氧基的单体来制备聚合物纳米颗粒的情况下,能够添加酸官能化单体,以与这些基团反应。这些单体的例子是(甲基)丙烯酸羟烷基酯,如甲基丙烯酸2-羟乙酯(“HEMA”),丙烯酸2-羟乙酯(“HEA”),甲基丙烯酸2-羟丙酯和乙酰乙酰氧基甲基丙烯酸酯。有用的含胺(甲基)丙烯酸酯包括甲基丙烯酸氨基乙酯和甲基丙烯酸二甲基氨基乙酯。有用的含硫单体包括2-丙烯酰氨基-2-甲基-1-丙磺酸,乙烯基磺酸和苯乙烯磺酸。
有用的含磷单体包括乙烯基膦酸和甲基丙烯酸膦酸乙酯。
可在本发明中使用的其它取代(甲基)丙烯酸酯单体可以包括含硅单体如(甲基)丙烯酸γ-丙基三(C1-C6)烷氧基甲硅烷基酯,(甲基)丙烯酸γ-丙基三(C1-C6)烷基甲硅烷基酯,(甲基)丙烯酸γ-丙基二(C1-C6)烷氧基(C1-C6)烷基甲硅烷基酯,(甲基)丙烯酸γ-丙基二(C1-C6)烷基(C1-C6)烷氧基甲硅烷基酯,(甲基)丙烯酸乙烯基三(C1-C6)烷氧基甲硅烷基酯,(甲基)丙烯酸乙烯基二(C1-C6)烷氧基(C1-C6)烷基甲硅烷基酯,(甲基)丙烯酸乙烯基(C1-C6)烷氧基二(C1-C6)烷基甲硅烷基酯,(甲基)丙烯酸乙烯基三(C1-C6)烷基甲硅烷基酯,和它们的混合物。在本发明中可用作不饱和单体的乙烯基芳族单体可以包括苯乙烯(“STY”),α-甲基苯乙烯,乙烯基甲苯,对甲基苯乙烯,乙基乙烯基苯,乙烯基萘,乙烯基吡啶,乙烯基二甲苯类,和它们的混合物。
在本发明中用作不饱和单体的烯属和取代烯属单体的例子可以包括环戊烯(环戊二烯),烯丙基类单体,乙烯基吡咯烷酮,乙酸乙烯酯,乙烯基甲酰胺,氯乙烯,氟乙烯,溴乙烯,偏二氯乙烯,偏二氟乙烯和偏二溴乙烯。
在本发明中用作单体的非烯属不饱和反应剂的例子可以包括能够通过加成或缩合反应合并成聚合物的多官能反应剂。有用的单体包括、但不限于醇类,酸类,胺类,卤化物,酰卤,异氰酸酯,酸酐,酯类,酰胺,烃氧基硅烷(alcoxysilane)等。适当的非限制性反应组合对本领域的那些技术人员来说是已知的,但包括实例如醇与异氰酸酯反应(如二异氰酸基己烷与己-1,6-二醇反应),酸与醇反应(如己二酸与己-1,6-二醇反应),酸酐与胺反应(如乙二胺与乙二胺四乙酸酐反应),以及卤化物与醇反应(如二碘乙烷与间苯二酚反应)。
另外,可降解的有机材料可以在本发明的方法中用作反应剂。可降解有机材料可以选自可以被光、热、水、酶和电磁辐射的作用所降解的化学族。所述化学族的实例包括、但不限于:二硫化物,羟基链烷酸酯,糖类,肽类,偶氮化合物,过氧化物,乙烯基化合物,活化碳酸酯类,活化酯类和酰胺。
另外,交联剂可以在本发明的方法中用作反应剂。交联剂包括、但不限于:二、三、四或更高的多官能烯属不饱和单体如乙二醇二丙烯酸酯,三羟甲基丙烷三丙烯酸酯,甲基丙烯酸烯丙酯(ALMA),乙二醇二甲基丙烯酸酯(EGDMA),DEGDMA,丙二醇二甲基丙烯酸酯,丙二醇二丙烯酸酯,TMPTMA,2,2-二甲基丙烷-1,3-二丙烯酸酯,1,3-丁二醇二丙烯酸酯,1,3-丁二醇二甲基丙烯酸酯,1,4-丁二醇二丙烯酸酯,二甘醇二丙烯酸酯,二甘醇二甲基丙烯酸酯,1,6-己二醇二丙烯酸酯,1,6-己二醇二甲基丙烯酸酯,三丙二醇二丙烯酸酯,三甘醇二甲基丙烯酸酯,四甘醇二丙烯酸酯,聚乙二醇200二丙烯酸酯,四甘醇二甲基丙烯酸酯,聚乙二醇二甲基丙烯酸酯,乙氧基化双酚A二丙烯酸酯,乙氧基化双酚A二甲基丙烯酸酯,聚乙二醇600二甲基丙烯酸酯,聚(丁二醇)二丙烯酸酯,季戊四醇三丙烯酸酯,三羟甲基丙烷三乙氧基三丙烯酸酯,甘油基丙氧基三丙烯酸酯,季戊四醇四丙烯酸酯(PETTA),季戊四醇四甲基丙烯酸酯(PETMA),和它们的混合物。可用于本发明的其它交联剂可以包括DVB,乙烯基脲烷,二烯丙基醚类,二烯丙基酯类,乙烯基聚酯,三乙烯基苯,二乙烯基甲苯,二乙烯基吡啶,二乙烯基萘和二乙烯基二甲苯,二甘醇二乙烯基醚,和三乙烯基环己烷,二溴乙烷,二甘醇,聚乙二醇,1,2-二氨基乙烷,丙二酸,双马来酰胺,三丙烯酸异氰脲酸酯,三烯丙基异氰脲酸酯,二烯丙氧基乙酸,甲苯二异氰酸酯,苧烯,脲,二溴丁烷。
为了与含硅树脂一起用于耐高温应用,交联剂可以优选包括含甲硅烷基的单体如二乙烯基硅烷,三乙烯基硅烷,二甲基二乙烯基硅烷,二乙烯基甲基硅烷,甲基三乙烯基硅烷,二苯基二乙烯基硅烷,二乙烯基苯基硅烷,含硅氧烷的单体如二甲基乙烯基二硅氧烷,聚(甲基乙烯基硅氧烷),聚(乙烯基氢化硅氧烷),聚(苯基乙烯基硅氧烷)和混合物。
另外,官能化聚合物和低聚物可以用作交联剂或可交联聚合物。在本发明中用作交联剂的适合的官能化聚合物包括、但不限于:由适当官能化乙烯基单体与包括、但不限于多元醇,如聚(乙二醇),聚(丙二醇),水解和部分水解聚(乙烯醇);聚(硅氧烷),如聚(二甲基)硅氧烷;聚(丙烯酸羟乙酯);聚(丙烯酸羟丙酯);聚(羟基苯乙烯);可降解聚合物如淀粉;糖类如葡萄糖,右旋糖,果糖,右旋糖酐,环糊精,纤维素,壳多糖,脱乙酰壳多糖的聚合物反应获得的丙烯酸酯和苯乙烯官能化均聚物和共聚物。适合用作交联剂的其它聚合物包括、但不限于官能化聚合物如:聚(烯丙基胺);聚丙烯酸;聚(丙烯酰氯);聚丙氨酸;聚(氨基苯乙烯);聚苯胺;聚(溴苯乙烯);聚丁二烯;聚酰胺和聚酯如聚羟基链烷酸酯;聚己内酯,聚己内酯二醇,聚对苯二甲酸乙二醇酯,尼龙-6,6;聚乙烯亚胺;聚(糠醇);聚(乙醇酸交酯);聚(交酯);聚乳酸;聚(衣康酸);聚(马来酸);聚(马来酸酐);聚(乙烯基胺);聚(氯乙烯);羟基、羧酸、卤素和氨基官能化树状体或超支化聚合物如聚酰胺型胺类;聚(苄醚),聚(烷基亚胺)。上述交联剂具有低于或等于10,000道尔顿的分子量。
本领域的技术人员清楚,本发明的方法可以通过诸如自由基,阴离子,阳离子,金属催化和缩合聚合机理以及偶联交联反应之类的技术来进行。
当反应机理是自由基聚合时,可用来实施本发明的引发剂例如包括以下的一种或多种:过酯,二烷基过氧化物,烷基氢过氧化物,过硫酸盐,偶氮引发剂,氧化还原引发剂等。可用的自由基引发剂包括、但不限于:过氧化苯甲酰,过辛酸叔丁酯,过氧新戊酸叔戊酯,氢过氧化枯烯,和偶氮化合物如偶氮异丁腈和2,2’-偶氮双(2-甲基丁腈)。自由基引发剂的用量一般是0.05-10wt%,基于全部单体的重量。在本发明的制备聚合物纳米颗粒的方法中,可以任选使用链转移剂。适合的链转移剂例如包括:烷基硫醇如十二烷基硫醇,亚磷酸类,具有活性氢的芳族烃类如甲苯,以及烷基卤化物如溴三氯甲烷和醇如异丙醇。
当反应机理是阴离子聚合时,可用来实施本发明的引发剂包括例如一种或多种强阴离子,如有机锂,有机钠,有机钾,格利雅试剂等。可用的阴离子引发剂包括、但不限于:丁基锂,萘基钠,液体氨,氨基化钾,叔丁醇钾,钾金属,戊基钠。示例性阴离子引发剂是丁基锂。阴离子引发剂的用量一般是0.05-10wt%,基于全部单体的重量。
当反应机理是阳离子聚合时,可用来实施本发明的引发剂包括例如一种或多种的质子酸,路易斯酸和/或能够产生阳离子的化合物,或电离辐射。可用的阳离子引发剂包括、但不限于:盐酸,甲磺酸,三氟化硼,三氯化铝,氯化锡,溴化锡,氯化锑,氯化钛(IV),二氯化锆,四氯化锆,碘。示例性阳离子引发剂是三氯化铝。阳离子引发剂的用量一般是0.05-10wt%,基于全部单体的重量。
当反应机理是金属催化的聚合,如易位,开环聚合,齐格勒-纳塔和原子转移自由基聚合时,可用来实施本发明的引发剂包括、但不限于过渡金属卤化物的配合物等。可用的金属催化聚合引发剂包括、但不限于:二氯·双(三环己基磷杂环戊二烯)苄叉基合钌(IV),2,6-二异丙基苯基亚氨基新苯叉基(2,6-diisopropylphenylphenylimidonephylidene)[(S)-BIPHEN]合钼(VI)(Schrock-Hoveyda催化剂),双(叔丁醇)·2,6-二异丙基苯基亚氨基新苯叉基合钼(VI),双(六氟叔丁醇)·2,6-二异丙基苯基亚氨基新苯叉基合钼(VI)(Schrock催化剂)。自由基引发剂的用量一般是0.05-10wt%,基于全部单体的重量。
当反应机理是缩合聚合时,可用来实施本发明的催化剂例如可以包括,但不限于以下的一种或多种:酸如盐酸,对甲苯磺酸,甲二磺酸,樟脑磺酸等;碱如醇碱如甲醇钠和甲醇钾等;金属乙酸盐如乙酸镉,乙酸锌,乙酸铅,乙酸钴,乙酸钡,乙酸镁;碱金属如钠和钾。该催化剂的用量一般是0.05-10wt%,基于全部单体的重量。
另外,无机纳米颗粒和无机前体可以用作反应剂,以形成高固体分聚合物纳米颗粒复合材料。
可用来实施本发明的无机纳米颗粒包括、但不限于粘土(合成和天然),二氧化硅(胶体,热解法和无定形),二氧化硅溶胶,二氧化钛,金属(氧化铝和氧化锆),金属氧化物(例如氧化铈,氧化铝,氧化钇,氧化锑),金属氮化物,无机颜料,金属碳化物,金属硫化物,金属硅酸盐,金属硼化物,金属碳酸盐,沸石和碳纳米管。无机颗粒的平均粒径例如是1-1000nm,又例如1-100nm和还例如2-50nm。
可用来实施本发明的无机前体包括、但不限于:有机硅烷,有机锆酸盐,有机钛酸盐,金属醇盐,金属二酮盐和金属羧酸盐。
本发明的聚合物纳米颗粒还可以通过沉淀聚合来制备。所谓“沉淀聚合”在本文中是指在使得所形成的聚合物不溶的溶剂中的聚合。
用本发明的方法制备聚合物纳米颗粒的一般程序如下所示:
能够通过首先将溶剂底料(heel)或溶剂和某些部分的反应剂的混合物加入到装有搅拌器、温度计和回流冷凝器的反应容器内来制备聚合物纳米颗粒。反应剂加料一般由单体、引发剂、聚合物和视需要而定的其它反应剂组成。其它反应剂可以任选与其它反应剂分开添加。在氮气笼罩下在搅拌的同时使溶剂或溶剂/反应剂底料加料达到适当的反应温度。典型的反应温度是-30℃到大约150℃,但更低或更高的温度是可能的。在底料达到足以引发反应的温度之后,将反应剂加料或剩余反应剂加料加入到反应容器内。总反应剂添加时间一般是15分钟到8小时,但实际上可以设想更短和更长的时间。
实施例
除在权利要求中限定外,以下实施例用来举例说明而不是限制本发明,除非另有规定,所有比率、百分率和比例按重量计,以及除非另有规定,所使用的所有试剂具有良好的商品质量。粒度测定通过使用MalvernHPPS的动态光散射技术或通过凝胶渗透色谱法来完成。
实施例1:BA/MMA/AA/TMPTA交联聚合物纳米颗粒的间歇反应器形成
给1000mL反应器装配热电偶,温度控制器,吹扫气体进口,具有吹扫气体出口的水冷回流冷凝器,搅拌器和加料漏斗。向加料漏斗添加36.4g的由12.25g丙烯酸丁酯、7g丙烯酸、12.25g甲基丙烯酸甲酯、3.5g三羟甲基丙烷三丙烯酸酯、1.4g的过氧新戊酸叔戊酯在矿油精中的75%溶液组成的单体混合物。含有400g 2-丙醇(IPA)的反应器然后用氮气吹扫30分钟,之后加热,使反应器的内容物达到80℃。当反应器的内容物达到80℃时,将在加料漏斗中的单体混合物加入到反应器中,再在该温度下保持90分钟。将如上所述的第二等份单体混合物加入到反应器中,随后是另外90分钟的保持时间。该脉冲添加重复另外四次。在最后一次单体混合物添加结束后的90分钟时,添加由2g的过新戊酸叔戊酯在矿油精中的75%溶液组成的追加投料(chaser shot)。在等份追加投料结束后,反应器的内容物在80℃下保持4小时,以完成反应。测得反应物具有35%的固体含量。在丙酮中通过动态光散射测定的平均粒径为4nm,粒径分布为2-20nm。
实施例2:BA/MMA/TMPTA交联纳米颗粒的间歇反应器形成
给1000mL反应器装配热电偶,温度控制器,吹扫气体进口,具有吹扫气体出口的水冷回流冷凝器,搅拌器和加料漏斗。向加料漏斗添加86g的由30g丙烯酸丁酯、30g甲基丙烯酸甲酯、6.7g三羟甲基丙烷三丙烯酸酯、2.7g的过新戊酸叔戊酯在矿油精中的75%溶液和16.7g 2-丙醇(“IPA”)组成的单体混合物。含有400g IPA的反应器然后用氮气吹扫30分钟,之后加热,使反应器的内容物达到79℃。当反应器的内容物达到79℃时,将在加料漏斗中的单体混合物加入到反应器中,再在该温度下保持90分钟。将如上所述的第二等份单体混合物加入到反应器中,随后是另外90分钟的保持时间。该脉冲添加过程重复另外四次。在单体混合物添加结束后的60分钟时,添加由8.0g的过新戊酸叔戊酯在矿油精中的75%溶液组成的追加投料。在第二等份追加投料结束后,反应器的内容物在80℃下保持30分钟,以完成反应。测得反应物具有47%的固体含量。通过凝胶渗透色谱法在四氢呋喃中测定的平均粒径为26nm。
预示(prophetic)实施例3:BA/MMA/TMPTA交联纳米颗粒的半连续反应器形成
串联装配三个反应器的系列。反应器A每30分钟之后补充来自转移漏斗的单体混合物和来自反应器C的再循环溶剂。反应器B是加热收集罐。反应器C是在真空下的溶剂反萃取罐。
反应器A是装配了连接于温度控制器的热电偶,吹扫气体进口,具有吹扫气体出口的水冷回流冷凝器,搅拌器,加料漏斗和从反应器A到反应器B的输送管路的1000mL反应器。向反应器A的加料漏斗添加86g的由30g丙烯酸丁酯、30g甲基丙烯酸甲酯、6.7g三羟甲基丙烷三丙烯酸酯、2.7g的过新戊酸叔戊酯在矿油精中的7 5%溶液和16.7g 2-丙醇(“IPA”)组成的单体混合物。反应器B是装配了连接于温度控制器的热电偶,吹扫气体进口,具有吹扫气体出口的水冷回流冷凝器,搅拌器,以及来自反应器A和到达反应器C的输送管路的1000mL反应器。反应器C是装配了连接于温度控制器的热电偶,具有馏出物收集器的水冷回流冷凝器和搅拌器的1000mL反应器。
将含有400g的无氧IPA的反应器A加热到79℃,之后,添加来自加料漏斗的单体混合物。让反应器A在该温度下保持30分钟,之后,将混合物泵送到反应器B。将如上所述的单体混合物和溶剂的第二批加料加入到反应器A中,以重新起动反应周期。反应器B的内容物在温度下保持30分钟的时间,之后,将反应器内容物泵送到反应器C。将反应器A的内容物转移到反应器B中。在真空中除去来自反应器C的内容物的溶剂,再转移到反应器A中,从而在反应器C中提供了干燥聚合物固体,收集该固体,之后,将反应器B的内容物转移到新排空的反应器C中。该方法能够连续操作。
预示实施例4:沉淀聚合形成BA/MMA/TMPTA交联纳米颗粒
给2000mL反应器装配热电偶,温度控制器,吹扫气体进口,具有吹扫气体出口的水冷回流冷凝器,搅拌器和加料漏斗。向加料漏斗添加86g的由30g丙烯酸丁酯、30g甲基丙烯酸甲酯、6.7g三羟甲基丙烷三丙烯酸酯、2.7g的过新戊酸叔戊酯在矿油精中的75%溶液和16.7g正癸烷组成的单体混合物。含有400g正癸烷的反应器然后用氮气吹扫30分钟,之后加热,使反应器的内容物达到79℃。当反应器的内容物达到79℃时,将在加料漏斗中的单体混合物加入到反应器中,再在该温度下保持90分钟。将如上所述的第二等份单体混合物加入到反应器中,随后是另外90分钟的保持时间。该脉冲添加过程重复另外四次。在单体混合物添加结束后的60分钟时,添加由8.0g的过新戊酸叔戊酯在矿油精中的75%溶液组成的相隔30分钟添加的双等份追加投料的第一份。在第二等份追加投料结束后,反应器的内容物在80℃下保持30分钟,以完成反应。最终固含量是45%。
预示实施例5:溶液聚合形成葡萄糖纳米颗粒
将丙烯酸(10g,1eq),氢醌(500ppm)和二环己基碳化二亚胺(32g,1.1eq)加入到在热二甲基甲酰胺(34g)中的葡萄糖(100g)中。将该混合物在60℃下搅拌8小时。过滤溶液,再冷却,之后将4,4’-偶氮双(4-氰基戊酸)(2g)和氢氧化钠(0.5g)加入到该上清液中,将该批料分成6等份。
给500mL反应器装配热电偶,温度控制器,吹扫气体进口,具有吹扫气体出口的水冷回流冷凝器,搅拌器和加料漏斗。向加料漏斗添加等份的以上大分子单体混合物。含有150g去离子水的反应器然后用氮气吹扫30分钟,之后加热,使反应器的内容物达到90℃。当反应器的内容物达到90℃时,将在加料漏斗中的大分子单体混合物加入到反应器中,再在该温度下保持90分钟。将如上所述的第二等份单体混合物加入到反应器中,随后是另外90分钟的保持时间。该脉冲添加过程重复另外四次。在单体加料程序结束之后,反应器的内容物在90℃下保持60分钟,以完成反应。最终固含量是44%。
预示实施例6:溶液聚合形成交联二甲基聚硅氧烷(聚甲基硅氧烷530)纳米颗粒
将丙烯酸(27g,2eq),氢醌(500ppm)和甲磺酸(3.6g,0.2eq)加入到在甲苯(34g)中的二甲基聚硅氧烷(100g)中。该混合物在Dean-Stark装置中回流,直到水放出全部停止为止。在冷却后,添加过新戊酸叔戊酯(2g),将该批料分成6等份。给500mL反应器装配热电偶,温度控制器,吹扫气体进口,具有吹扫气体出口的水冷回流冷凝器,搅拌器和加料漏斗。向加料漏斗添加等份的以上大分子单体混合物。含有150g甲苯的反应器然后用氮气吹扫30分钟,之后加热,使反应器的内容物达到79℃。当反应器的内容物达到79℃时,将在加料漏斗中的大分子单体混合物加入到反应器中,再在该温度下保持90分钟。将如上所述的第二等份单体混合物加入到反应器中,随后是另外90分钟的保持时间。该脉冲添加过程重复另外四次。在单体混合物添加结束后的60分钟时,添加由8.0g的过新戊酸叔戊酯在矿油精中的75%溶液和20g甲苯组成的相隔30分钟添加的双等份追加投料的第一份。在第二等份追加投料结束后,反应器的内容物在80℃下保持60分钟,以完成反应。最终固含量是40%。
预示实施例7:在蒙脱土的存在下通过溶液聚合形成BA/MMA/AA/TMPTA聚合物纳米颗粒
给1000mL反应器装配热电偶,温度控制器,吹扫气体进口,具有吹扫气体出口的水冷回流冷凝器,搅拌器和加料漏斗。向加料漏斗添加36.4g的由12.25g丙烯酸丁酯、7g丙烯酸、12.25g甲基丙烯酸甲酯、3.5g三羟甲基丙烷三丙烯酸酯、1.4g的过新戊酸叔戊酯在矿油精中的75%溶液组成的单体混合物。含有400g IPA和1g蒙脱土的反应器然后用氮气吹扫30分钟,之后加热,使反应器的内容物达到80℃。当反应器的内容物达到80℃时,将在加料漏斗中的单体混合物加入到反应器中,再在该温度下保持90分钟。将如上所述的第二等份单体混合物加入到反应器中,随后是另外90分钟的保持时间。该脉冲添加过程重复另外四次。在最后一次单体混合物添加结束后的90分钟时,添加由2g的过新戊酸叔戊酯在矿油精中的75%溶液组成的追加投料。在等份追加投料结束后,反应器的内容物在80℃下保持4小时,以完成反应。最终固含量是34%。
预示实施例8:通过交联反应形成交联聚苯乙烯-聚乙烯基吡啶共聚物
给250mL反应器装配热电偶,温度控制器,吹扫气体进口,具有吹扫气体出口的水冷回流冷凝器,搅拌器和加料漏斗。向加料漏斗添加5g的聚苯乙烯-聚乙烯基吡啶共聚物和1g的1,4-二溴丁烷在5g二噁烷中的反应混合物。含有50g二噁烷的反应器然后用氮气吹扫30分钟,之后加热,使反应器的内容物达到90℃。当反应器的内容物达到90℃时,将在加料漏斗中的反应混合物加入到反应器中,再在该温度下保持90分钟。将如上所述的第二等份反应混合物加入到反应器中,随后是另外90分钟的保持时间。该脉冲添加过程重复另外六次。在最后一次等份部分添加结束时,反应器的内容物在90℃下保持3小时,以完成反应。最终固含量是35%。
Claims (7)
1.制备聚合物纳米颗粒的方法,包括将溶剂和反应剂加入到容器内和让所述反应剂反应,以形成交联聚合物纳米颗粒,其中,所述反应剂包含单体(甲基)丙烯酸烷基酯、脂环族(甲基)丙烯酸酯、(甲基)丙烯酰胺、乙酸乙烯酯、(甲基)丙烯酸链烯基酯、(甲基)丙烯酸芳基酯、(甲基)丙烯酸烷芳基酯、含胺的(甲基)丙烯酸酯、含磷的(甲基)丙烯酸酯、含硫的(甲基)丙烯酸酯、乙烯基芳族单体、(甲基)丙烯酸、取代的烯类单体、以及它们的混合物;所述反应剂还包含交联剂;所述聚合物纳米颗粒具有1-50nm的平均粒径;该方法是非乳液方法,并且该方法获得了含有聚合物纳米颗粒的分散体,该分散体具有等于或高于45wt%的聚合物纳米颗粒的固含量;该方法选自溶液聚合、分散体聚合、悬浮聚合和沉淀聚合,反应温度为-30℃至150℃。
2.根据权利要求1的方法,其特征在于,该方法选自间歇方法,半连续方法,和连续方法。
3.根据权利要求1的方法,其特征在于,以至少两个等份部分将所述反应剂加入到容器内。
4.根据权利要求1的方法,其特征在于,所述反应剂还包含含有反应性基团的官能化聚合物。
5.根据权利要求1的方法,其特征在于,所述反应剂还包含无机材料。
6.根据权利要求1的方法,其特征在于,在添加完反应剂之前,具有其中不进给反应剂的时间间隔。
7.根据权利要求6的方法,其特征在于,所述时间间隔为30秒钟至8小时。
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