Formaldehyde homopolymer

Formaldehyde homopolymer is composed exclusively of repeating oxymethylene units and is described by the term poly oxymethylene (POM) [9002-81-7]. Commercially significant copolymers, for example [95327-43-8] have a minor fraction (typically less than 5 mol %) of alkyUdene or other units, derived from cycHc ethers or cycHc formals, distributed along the polymer chain. The occasional break in the oxymethylene sequences has significant ramifications for polymer stabilization. 

Although there is a substantial body of information in the pubHc domain concerning the preparation of polyacetals, the details of processes for manufacturiag acetal resins are kept highly confidential by the companies that practice them. Nevertheless, enough information is available that reasonably accurate overviews can be surmised. Manufacture of both homopolymer and copolymer involves critical monomer purification operations, discussion of which is outside the scope of this article (see Formaldehyde). Homopolymer and copolymer are manufactured by substantially different processes for accomplishing substantially different polymerisation chemistries. 

Gak et al. (100, 102) examined the nature of free radicals in polyoxymethylene. When formaldehyde homopolymer, PFA-OH was irradiated at —196° C, the initial rate of formation of the free radical — CH20- was found to be proportional to the square of the incident light intensity, which indicates the two-photon process of —CH20-radical formation. When irradiated PFA-OH was kept in the dark, some increase occurred in the concentration of -CH20- and there was a simultaneous fall in the concentration of -CH2 at temperatures above —196° C. The maximum rate was attained in the temperature range —130° C----123° C. This is caused by reaction (41). 

Table 8.1. Typical values for various properties of formaldehyde homopolymer and copolymer.

Homopolymer. Acetal homopolymers are prepared from formaldehyde and consist of high-molecular-weight linear polymers of formaldehyde. 

The term "acetal resins" commonly denotes the family of homopolymers and copolymers whose main chains are completely or essentially composed of repeating oxymethylene units (—CH2—O—). The polymers are derived chiefly from formaldehyde or methanal [50-00-00] either directly or through its cychc trimer, trioxane or 1,3,5-trioxacyclohexane [110-88-3]. 

Homopolymer. Formaldehyde polymerises by both anionic and cationic mechanisms. Strong acids are needed to initiate cationic polymerisation. Anionic polymerisation, which can be initiated by relatively weak bases (eg, pyridine), can be represented by the following equations Initiation... 

Acetal Resins. These are high performance plastics produced from formaldehyde that are used for automotive parts, in building products, and in consumer goods. Acetal resins (qv) are either homopolymers or copolymers of formaldehyde. Typically, the resin is produced from anhydrous formaldehyde or trioxane. The acetal resins formaldehyde demand are 9% of production (115). 

Uses ndReactions. Some of the principal uses for P-pinene are for manufacturing terpene resins and for thermal isomerization (pyrolysis) to myrcene. The resins are made by Lewis acid (usuaUy AlCl ) polymerization of P-pinene, either as a homopolymer or as a copolymer with other terpenes such as limonene. P-Pinene polymerizes much easier than a-pinene and the resins are usehil in pressure-sensitive adhesives, hot-melt adhesives and coatings, and elastomeric sealants. One of the first syntheses of a new fragrance chemical from turpentine sources used formaldehyde with P-pinene in a Prins reaction to produce the alcohol, Nopol (26) (59). 

Acetals. Acetal resins (qv) are polymers of formaldehyde and are usually called polyoxymethylene [9002-81-7]. Acetal homopolymer was developed at Du Pont (8). The commercial development of acetal resins required a pure monomer. The monomer is rigorously purified to remove water, formic acid, metals, and methanol, which act as chain-transfer or reaction-terminating agents. The purified formaldehyde is polymerized to form the acetal homopolymer the polymer end groups are stabilized by reaction with acetic anhydride to form acetate end groups (9). 

Acetal Resins. Acetal resins (qv) are poly (methylene oxide) or polyformaldehyde homopolymers and formaldehyde [50-00-0] copolymeri2ed with ahphatic oxides such as ethylene oxide (42). The homopolymer resin polyoxymethylene [9002-81-7] (POM) is produced by the anionic catalytic polymeri2ation of formaldehyde. For thermal stabiUty, the resin is endcapped with an acyl or alkyl function. 

The first commercially available acetal resin was marketed by Du Pont in 1959 under the trade name Delrin after the equivalent of ten million pounds had been spent in research or polymers of formaldehyde. The Du Pont monopoly was unusually short lived as Celcon, as acetal copolymer produced by the Celanese Corporation, became available in small quantities in 1960. This material became commercially available in 1962 and later in the same year Farbwerke Hoechst combined with Celanese to produce similar products in Germany (Hostaform). In 1963 Celanese also combined with the Dainippon Celluloid Company of Osaka, Japan and Imperial Chemical Industries to produce acetal copolymers in Japan and Britain respectively under the trade names Duracon and Alkon (later changed to Kematal). In the early 1970s Ultraform GmbH (a joint venture of BASF and Degussa) introduced a copolymer under the name Ultraform and the Japanese company Asahi Chemical a homopolymer under the name Tenal. 

Homopolymers and copolymers from amido-sulfonic acid or salt containing monomers can be prepared by reactive extrusion, preferably in a twin screw extruder [1660]. The process produces a solid polymer. Copolymers of acrylamide, N-vinyl-2-pyrrolidone, and sodium-2-acrylamido-2-methyl-propane sulfonate have been proposed to be active as fluid loss agents. Another component of the formulations is the sodium salt of naphthalene formaldehyde sulfonate [207]. The fluid loss additive is mixed with hydraulic cements in suitable amounts. 

Formaldehyde solutions prepared by dissolving and depolymerization of paraformaldehyde (a homopolymer of formaldehyde with empirical formula HO (CH20)nH, where n > 6) are free of admixtures of methanol and formic acid. Depolymerized paraformaldehyde is useful in enzyme histochemistry, when the preservation of the enzyme activity is of crucial importance, but it has no advantage over formalin solutions routinely used in pathology and in immunohistochemistry. 

Crospovidone is a cross-linked homopolymer of A-vinyl-2-pyrrolidone. Acetylene and formaldehyde react to form butynediol. Hydrogenation and subsequent cyclodehydrogenation gives butyrolactone. The reaction of butyrolactone with ammonia produces pyrrolidone, which is vinylated with acetylene under pressure. The linear polymerization of the vinylpyrrolidone yields polyvinylpyrrolidone, a soluble binder, whereas the popcorn (branched) polymerization yields crospovidone, an insoluble... 

The industrial synthesis of polyformaldehyde [poly(oxymethylene)] occurs by anionic polymerization of formaldehyde in suspension. For this the purification and handling of monomeric formaldehyde is of special importance since it tends to form solid paraformaldehyde. After the polymerization the semiacetal end groups have to be protected in order to avoid thermal depolymerization (Example 5-13). This is achieved by esterfication with acetic anhydride (see Example 5-7). As in the case of trioxane copolymers (see Sect. 3.2.3.2) the homopolymers of formaldehyde find application as engineering plastics. 

Finally, it should be mentioned that there exist two other routes for the synthesis of copolymers. First the partial chemical conversion of homopolymers (see Sect. 5.1), for example, the partial hydrolysis of poly(vinyl acetate). Secondly, by homopolymerization of correspondingly built monomers. An example for these macromolecular compounds, sometimes called pseudo-copolymers, is the alternating copolymer of formaldehyde and ethylene oxide synthesized by ringopening polymerization of 1,3-dioxolane. 

RESINS (Acetal). These are thermoplastic resins, obtainable both as homopolymers and copolymers, and produced principally from formaldehyde or formaldehyde derivative. Acetal resins have the highest fatigue endurance of commercial thermoplastics. A variety of ionic initiators, such as tertiary amines and quaternary ammonium salts, are used to effect polymerization of formaldehyde. Chain transfer, shown by the following reactions, controls the molecular weight of resulting resins ... 

Homopolymer. Acetal homopolymers are prepared from formaldehyde and consist of high-molecular-weight linear polymers of formaldehyde. The trimer of formaldehyde is shown to the left and the structure of the polymer is shown at the right, below. 

Polyformaldehyde. Polyformaldehyde or polyacetal is made by two different processes. Delrin is made from formaldehyde by anionic polymerization catalyzed by a tertiary amine. The homopolymer is end-capped with acetic anhydride. Celcon is made from trioxane cationic copolymerization using boron trifluoride catalyst and ethylene oxide (2-3%) as the comonomer. Boron trifluoride is a Lewis acid that associates with trioxane and opens up the six-membered ring. Ethylene oxide provides the end capping. Without an end cap, polyformaldehyde is thermally unstable and loses formaldehyde units. 

It also can be produced directly from natural gas, methane, and other aliphatic hydrocarbons, but this process yields mixtures of various oxygenated materials. Because both gaseous and liquid formaldehyde readily polymerize at room temperature, formaldehyde is not available in pure form. It is sold instead as a 37 percent solution in water, or in the polymeric form as paraformaldehyde [HO(CH20)nH], where n is between 8 and 50, or as trioxane (CH20)3. The greatest end use for formaldehyde is in the field of synthetic resins, either as a homopolymer or as a copolymer with phenol, urea, or melamine. It also is reacted with acetaldehyde to produce pentaerythritol [C(CH2OH)4], which finds use in polyester resins. Two smaller-volume uses are in urea-formaldehyde fertilizers and in hexamethylenetetramine, the latter being formed by condensation with ammonia. 

The polyoxymethylenes are presently widely used in different areas. Approximatively one-third of the market is represented by homopolymers and two-thirds by copolymers. Homopolymers are produced by anionic polymerization of formaldehyde using amines, alkoxides, and other types of anionic initiators. The details of these polymerizations will not be discussed in this paper, although some of their properties will be compared to those of copolymers which are obtained by cationic copolymerization of trioxane with cyclic ethers or cyclic esters. Comprehensive reviews on general aspects of synthesis and properties of acetal resins are available [158-162],... 

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