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Emulsion radical polymerization processes have created considerable wealth in many industrial sectors, including coatings, adhesives, paints, additives for textiles and paper… Traditionally, waterborne polymer dispersions are produced in stirred tank reactors by the thermally-activated free-radical polymerization of a starting monomer emulsion. The objective of this project is to exploit UV radiation to promote the formation of high solid contents polymer latexes. The breakthrough is to generate highly concentrated dispersions of monomer nanodroplets (< 100 nm), that are subsequently photopolymerized in a specially designed photochemical reactor to produce polymer nanoparticles. Replacing a thermal process by a photochemical one has several advantages: (i) UV irradiation can induce very high rates of initiation that directly affect the overall rate of polymerization. In fact, the radical generation is known to be controlled by the incident photon flux and by the absorption conditions of the reaction system inside the photochemical reactor. Remaining within the nanometric (submicrometric) size range, the ratio of light absorption vs. scattering will be optimized in order to work under best conditions as far as light penetration is concerned. (ii) Photopolymerization will favour the implementation of continuous processes replacing the production limiting semi-batch operations used nowadays in industry. (iii) Photochemically initiated radical polymerizations are generally temperature independent and bear a much higher potential of application due to defined solubility, emulsion stabilization and controlled polymerization kinetics. (iv) A photochemical technology also complies with impeding European directives on solvent emissions and energy reductions. A viable emulsion photopolymerization process can thus impart a wide range of attractive advantages of process intensification, but there is currently no mature technology in this field. To achieve this objective, the PHOTOEMULSION project will integrate contributions from two academic laboratories and an industrial partner: the Laboratoire de Photochimie et d'Ingénierie Macromoléculaires (LPIM, Université of Haute Alsace, Mulhouse), the Laboratoire des Interactions Moléculaires et Réactivité Chimique et Photochimique (IMRCP, Université Paul Sabatier, Toulouse III) and the MÄDER group. The LPIM (ex-Department of Phochemistry) is internationally recognized in the development of radiation-curing technology while the IMRCP has a complementary expertise in the domains of photochemical technology and engineering. A major change from the initial project submitted in 2010 is the involvement of MÄDER, responsible for planning and upscaling process innovations. MÄDER has a well-established activity in the sector of industrial and decorative coatings, and has been a pioneer company in the design and use of water-based paints and bio-sourced resins/monomers. As a result of the project, an innovative photopolymerization process in water will be introduced and applied in the highly technical market segment of bio-sourced latexes.
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