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 Process for producing telechelic, branched and star thermoplastic resin polymers

Details
Inventors: Moffat, Karen A.; Kazmaier, Peter M.; Hamer, Gordon K.; Georges, Michael K.;
Assignee: Xerox Corporation (Stamford, CT)
Primary Examiner: Nagumo; Mark
Assistant Examiner:
Attorney, Agent or Firm: Oliff & Berridge

A free radical polymerization process for the preparation of a thermoplastic resin or resins includes heating a mixture of a multifunctional nitroxide compound and at least one polymerizable monomer compound to form a thermoplastic resin or resins; cooling the mixture; and optionally isolating and washing and drying the thermoplastic resin. A multifunctional nitroxide compound for use in the reaction is formed from a stable free radical agent and a compound having one or more halide functional groups. The free radical polymerization process may be used to prepare telechelic, branched and star polymers.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS The free radical polymerization process of the present invention may be used to prepare a variety of telechelic, branched and star polymers and copolymers with a variety of molecular architectures in a cost efficient manner.
An advantage of the present invention is that the stable free radical polymerization process affords precise control over the molecular architecture of the polymer, including molecular weight, molecular weight distribution and modality.
The polymers may generally be produced by the two-step process of: (a) generating a multifunctional nitroxide compound by reacting a nitroxide stable free radical agent with an alkyl or aryl halide or .
alpha.
-keto halide reagent having reactive halide functional groups, in the presence of a hydride generating compound; and (b) using the multifunctional nitroxide compound to polymerize one or more monomers by a stable free radical polymerization process.
In embodiments, it may be possible to increase the efficiency of the polymerization process of the present invention by both generating the multifunctional nitroxide compound and polymerizing the monomer or monomers in the same reaction vessel, without first isolating the multifunctional nitroxide compound.
These processes may, for example, be used to produce thermoplastic resins, including telechelic, branched and star polymer and block copolymer resins, having a number average molecular weight in the range of from about 1,000 to about 1,000,000.
Stable free radical agents are known in the literature.
For example G.
Moad et al.
, Tetrahedron Letters, 22, 1165 (1981), which is totally incorporated herein by reference, discloses stable free radical agents as free radical polymerization inhibitors.
However, under the free radical polymerization conditions of the present invention, stable free radical agents function as moderators to harness the normally highly reactive and indiscriminate intermediate free radical species.
Stable free radical agents as reaction moderators are disclosed in U



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