Flow reactor synthesis of polymers

Abstract

A flow reactor system and methods having tubing useful as polymerization chamber. The flow reactor has at least one inlet and at least one mixing chamber, and an outlet. The method includes providing two phases, an aqueous phase and a non-aqueous phase and forming an emulsion for introduction into the flow reactor.

What is claimed is: 
     
       1. A method comprising: 
 introducing an emulsion of a monomer and an acid into a flow reactor, the flow reactor comprising a length of tubing of inner diameter between about 1 to about 1000 micrometers; 
 polymerizing the monomer; and 
 forming a salt of the polymerized monomer with the acid within the length of tubing, and maintaining the salt of the polymerized monomer in the length of tubing. 
 
     
     
       2. The method of  claim 1 , further comprising introducing a catalyst to the emulsion. 
     
     
       3. The method of  claim 1 , further comprising introducing a catalyst to the flow reactor. 
     
     
       4. The method of  claim 1 , wherein the emulsion comprises an aqueous solution of the monomer and an organic solvent solution of the acid. 
     
     
       5. The method of  claim 1  further comprising maintaining the salt of the polymerized monomer in the length of tubing. 
     
     
       6. The method of claim  5 1, further comprising recovering the salt of the polymerized monomer from the tubing. 
     
     
       7. The method of  claim 6 , wherein the recovering of the salt of the polymerized monomer from the tubing is with organic solvent. 
     
     
       8. The method of  claim 1 , further comprising maintaining the polymerized acid salt in the length of tubing and removing unreacted monomer or the acid from the tubing with water. 
     
     
       9. The method of  claim 1 , wherein the length of tubing is coiled. 
     
     
       10. The method of  claim 1 , wherein the tubing is a fluoropolymer. 
     
     
       11. The method of  claim 1 , wherein the flow reactor comprises a plurality of tubing arranged in a parallel flow configuration. 
     
     
       12. The method of  claim 1 , wherein the polymerizing is carried out in a diffusion-limiting condition. 
     
     
       13. The method of  claim 1 , wherein the monomer is an aniline or a thiophene. 
     
     
       14. The method of  claim 1 , wherein the acid is an organic acid selected from polystyrene sulfonate or dinonylnaphthalene sulfonic acid. 
     
     
       15. A method comprising: 
 introducing an emulsion of an aniline and an organic sulfonic acid; 
 introducing the emulsion into a flow reactor, the flow reactor comprising a length of tubing of inner diameter between about one to about 1000 micrometers; 
 introducing an oxidant to the emulsion or the flow reactor; and 
 polymerizing the aniline in the inner diameter of the length of tubing and forming an acid salt thereof, and maintaining the salt of the polymerized monomer in the length of tubing. 
 
     
     
       16. A polymerization apparatus for reacting one or more monomers producing one or more polymers, the polymerization apparatus comprising:
 an amount of tubing of inner diameter between about 1 to about 1000 micrometers, the tubing including at least one inlet and at least one outlet, the amount of tubing having at least one inlet port for receiving a reactant composition and at least one outlet port; 
 a temperature controller sized to receive at least a portion of the tubing; 
 a mixing chamber, the mixing chamber having an outlet fluidically coupled to the inlet of the tubing, and an inlet; 
 at least one pressure unit operatively coupled to one or both of the inlet port or the outlet port of the amount of tubing, the at least one pressure unit configured to monitor, during polymerization of the one or more monomers, pressure in the amount of tubing or the difference in pressure between the inlet port and the outlet port of the amount of tubing; and 
 at least one fluid flow control device fluidically coupled to the inlet of the mixing chamber, 
 a first fluid line fluidically coupled to the amount of tubing to introduce collecting medium comprising an organic solvent into the amount of tubing for collecting polymerization product from an inner wall of the amount of tubing; and 
 a second fluid line fluidically coupled to the amount of tubing to introduce purging medium into the amount of tubing. 
 
     
     
       17. The polymerization apparatus of  claim 16 ;,wherein the tubing is wound around the temperature controller. 
     
     
       18. The polymerization apparatus of  claim 16 ;, wherein the at least one fluid control device comprises a monomer fluid flow control device and an acid fluid flow control device. 
     
     
       19. The polymerization apparatus of  claim 16 , further comprising a second mixing chamber fluidically coupled to the outlet of the mixing chamber and the inlet of the tubing. 
     
     
       20. The polymerization apparatus of  claim 16 , further comprising a catalyst fluid flow control device fluidically coupled to the second mixing chamber or to the tubing. 
     
     
       21. A flow reactor for reacting one or more monomers producing one or more polymers, the flow reactor comprising:
 a tubing, comprising at least one inlet port for receiving an emulsion reactant composition and at least one outlet port;   a temperature controller sized to receive at least a portion of the tubing;   a mixing chamber, the mixing chamber comprising an inlet and an outlet fluidically coupled to the inlet of the tubing;   at least one pressure unit operatively coupled to one or both of the inlet port or the outlet port of the tubing, the at least one pressure unit configured to monitor, during polymerization of the one or more monomers, pressure in the tubing or the difference in pressure between the inlet port and the outlet port of the tubing;   at least one fluid flow control device fluidically coupled to the inlet of the mixing chamber,   a first fluid line fluidically coupled to the tubing to introduce collecting medium comprising an organic solvent into the tubing for collecting polymerization product from an inner wall of the tubing; and   a second fluid line fluidically coupled to the tubing to introduce purging medium into the tubing.    
     
     
       22. The flow reactor of claim 21, wherein an inner diameter of the tubing is sized for diffusion limited polymerization.  
     
     
       23. The flow reactor of claim 21, wherein an inner diameter of the tubing is between about 1000 micrometers to about 4000 micrometers.  
     
     
       24. The polymerization apparatus of claim 16, wherein the at least one pressure unit is configured to monitor back pressure.  
     
     
       25. The flow reactor of claim 21, wherein the at least one pressure unit is configured to monitor back pressure.