Control over controlled radical polymerization processes

1. A polymer manufacturing process, comprising:

a) forming a mixture in a reactor, comprising combining:

i) at least a first free-radically polymerizable compound;

ii) an atom transfer radical polymerization initiator;

iii) a metal catalyst; and

iv) optionally, a ligand;

b) initiating polymerization by adding an initial amount of a non-activated reducing agent at a first temperature to transform the metal catalyst to an active metal catalyst or regenerate the active metal catalyst; and

c) minimizing or preventing uncontrolled exotherms during the polymerization process by adding further amounts of the non-activated reducing agent at a controlled rate of addition to regenerate the active metal catalyst.

2. The process of claim 1 , wherein the controlled rate of addition of the further amounts of the non-activated reducing agent:

a) controls propagation of polymeric chains formed in the polymerization mixture; or

b) maintains the polymerization mixture at or above the first temperature; or

c) combinations thereof.

3. The process of claim 1 , wherein the controlled rate of addition comprises continuous, non-continuous, periodic, intermittent, adjustable, or combinations thereof.

4. The process of claim 1 , wherein the polymerization process allows conversion of the at least first free-radically polymerizable compound to exceed 80% conversion.

5. The process of claim 1 , wherein the at least first free-radically polymerizable compound is an unsaturated monomer.

6. The process of claim 1 , wherein:

a) the metal catalyst is an inactive metal-halide catalyst; and

b) the active metal catalyst is an active metal-halide catalyst.

7. The process of claim 1 , wherein the polymer manufacturing process is conducted in a bulk polymerization process; is performed in the presence of a solvent; is conducted from solid surfaces; or is conducted in a biphasic polymerization process, an emulsion polymerization process, a mini-emulsion polymerization process, a microemulsion polymerization process, a reverse emulsion polymerization process, or a suspension polymerization process.

8. The process of claim 1 , wherein the resulting polymer is a linear polymer or copolymer, a branched polymer or copolymer, a block copolymer, a brush polymer or copolymer, a star polymer or copolymer, or a star macromolecule.

9. The process of claim 1 , wherein the non-activated reducing agent is a free-radical initiator.

10. The process of claim 1 , wherein the controlled rate of addition of the further amounts of the non-activated reducing agent is adjusted relative to changes in the temperature of the polymerization process.

11. The process of claim 1 , wherein the polymerization process further comprises adding one or more further amounts of the metal catalyst, and optionally, a ligand.

12. The process of claim 1 , wherein the polymerization process further comprises adding one or more further amounts of the at least a first free-radically polymerizable compound.

13. The process of claim 1 , wherein the polymerization process is maintained at or above conditions wherein the non-activated reducing agent has an activation-dependent t 1/2 value of between 30 sec. and 30 min.

14. The process of claim 1 , wherein the process further comprises:

a) polymerizing at least a second free-radically polymerizable compound at an at least a second polymerizing temperature in the reactor;

b) polymerizing a plurality of free-radically polymerizable compounds at a corresponding plurality of polymerizing temperatures in the reactor; or

c) cross-linking the polymerization mixture at a cross-linking temperature in the reactor; or

d) combinations thereof.

15. The process of claim 14 , wherein the polymerization of the at least second free-radically polymerizable compound comprises:

a) adding to the polymerization mixture comprising polymer of the at least first free-radically polymerizable compound:

i) the at least second free-radically polymerizable compound; and

ii) optionally, adding at least a second metal catalyst and a ligand;

b) optionally, adjusting the temperature of the polymerization mixture to the at least second polymerizing temperature;

c) initiating polymerization by adding an initial amount of at least a second non-activated reducing agent to regenerate the active metal catalyst or transform the optional at least second metal catalyst to an at least second active metal catalyst; and

d) propagating polymeric chains formed in the mixture and maintaining the polymerization at or above the at least second temperature by adding further amounts of the at least second non-activated reducing agent at a controlled rate of addition.

16. The process of claim 14 , wherein the polymerization of the plurality of free-radically polymerizable compounds comprises:

a) adding to the polymerization mixture comprising polymer of the at least first free-radically polymerizable compound:

i) at least a second free-radically polymerizable compound; and

ii) optionally, adding at least a second metal catalyst and a ligand;

b) optionally, adjusting the temperature of the polymerization mixture to at least a second temperature;

c) initiating polymerization of the at least second free-radically polymerizable compound by adding an initial amount of at least a second non-activated reducing agent to regenerate the active metal catalyst or transform the optional at least second metal catalyst to an at least second active metal catalyst; and

d) propagating polymeric chains formed in the mixture and maintaining the polymerization at or above the at least second temperature by adding further amounts of the at least second non-activated reducing agent at a controlled rate of addition.

17. The process of claim 16 , wherein the temperature of the polymerization mixture is adjusted to the at least second polymerizing temperature using a heating source or cooling source or adjusting the controlled addition rate of the second non-activated reducing agent.

18. The process of claim 14 , wherein the cross-linking of the polymerization mixture comprises:

a) adding to the polymerization mixture comprising polymer of the at least first free-radically polymerizable compound:

i) adding a cross-linker to the polymerization mixture; and

ii) optionally, adding a further metal catalyst and a ligand;

b) optionally, adjusting the temperature of the polymerization mixture to a further temperature;

c) initiating cross-linking of the cross-linker by adding an initial amount of a further non-activated reducing agent to regenerate the active metal catalyst or transform the optional further metal catalyst to a further active metal catalyst; and

d) cross-linking polymeric chains formed in the mixture and maintaining the cross-linking at or above the further temperature by adding further amounts of the further non-activated reducing agent at a controlled rate of addition.