Development of an ab initio emulsion atom transfer radical polymerization: from microemulsion to emulsion.

Atom transfer radical polymerization (ATRP) has been successfully extended to an ab initio emulsion system using a "two-step" procedure, in which the final emulsion polymerization system was formed by adding monomer to an ongoing microemulsion ATRP. The newly developed AGET (activators generated by electron transfer) initiation technique was employed in the first stage of this ab initio ATRP. It allows using oxidatively stable Cu(II) species that is reduced in situ by ascorbic acid. The surfactant concentration in the final emulsion system was efficiently decreased to approximately 2 wt % (approximately 10 wt % vs monomer) by decreasing the catalyst concentration and changing the ratio of the monomer added at the microemulsion stage to the monomer added during the second stage. This two-step procedure avoids the necessity of transporting catalysts through the aqueous media during polymerization, resulting in a controlled emulsion polymerization, as evidenced by a linear first-order kinetic plot and formation of a polymer with a relatively narrow molecular weight distribution (Mw/Mn = 1.2-1.4). The polymerization typically reached 70-90% monomer conversion in 5-6 h. The resulting polymer had high chain-end functionality and was successfully chain extended to form in situ block copolymers by adding the second monomer to an ongoing emulsion polymerization. The stable latex from the ab initio emulsion ATRP had a particle size approximately 120 +/- 10 nm.