Process for producing homopolymers or copolymers of vinyl or vinylidene halides by emulsion polymerization

Claim 1

A process for producing polymers of vinyl and vinylidene halides and copolymers thereof with each other or either with one or more vinylidene monomers having at least one terminal CH 2 ═C< grouping comprising forming a monomer premix containing the monomer or monomers to be polymerized, the aqueous reaction medium, from about 0.01% to about 0.5% by weight of a free-radical yielding catalyst based on the weight of 100 parts of monomer or monomers being polymerized, from about 0.0 to about 0.5 part of an ammonium salt of a saturated fatty acid containing from 8 to 20 carbon atoms, at least one long straight chain saturated alcohol containing from 14 to 24 carbon atoms, and from about 0.5 to about 1.25 parts of a sulfate or sulfonate type soap having the general formula CH.sub.3 (C.sub.n H.sub.2n)--X wherein n is an integer from 7 to 17, X is selected from the group consisting of ##STR2## and wherein R is H, OH or an alkyl group containing from 1 to 4 carbon atoms; R is H, or an alkyl group containing from 1 to 4 carbon atoms; Y is --SO 3 --M; --O--SO 3 --M; or --OCH 2 CH 2 --O-- m SO 3 --M, wherein M is selected from NH 4 , Na and K, and m is an integer from 7 to 17, the ratio of alcohol to emulsifier is equal to or greater than 1.0, homogenizing said premix at a temperature below the reactivity of the catalyst or catalysts employed, passing said homogenized premix to a reaction zone, initially polymerizing said homogenized premix in said zone at a temperature in the range of 30° C. to 40° C., then continuing the polymerization in said zone at a temperature in the range of about 40° C. to about 65° C. until complete, maintaining the pH in the reaction zone in the range of about 7.0 to about 12.0 throughout the polymerization reaction period, and thereafter recovering the polymer or copolymer latex or slurry and spray drying the same, whereby polymers and copolymers having improved plastisol foam properties are produced and polymer buildup in said reaction zone is substantially reduced.