Preparation methyl methacrylate

Direct esterification of methacrylic acid with alcohols using sulfuric acid or other catalysts can be used to prepare methyl methacrylate (MMA) and other esters. Commercial routes for the direct preparation of MMA and some lower alkyl esters also exist. In the 1990s, researchers at Shell developed a direct route to MMA from propyne (methylacetylene), carbon monoxide, and methanol using a Pd(II) catalyst. The limited availability of propyne may slow the expansion of this highly efficient route to high purity MMA. Transesterification of MMA is often the preferred route for the preparation of other esters. 

Pansier [2] used the bromomethyl analogue, (II), of the Step 2 product in the atom transfer radical polymerization of methyl methacrylate. Lewandowski [3] prepared the tribromomethyl analogue, (111), by reacting with trimethylolpro-pane and then used this reagent to prepare methyl methacrylate star polymers. A reaction profile is provided in Table 3. 

Polylmethyl Methacrylate). The monomer used for poly(methyl methacrylate), 2-hy-droxy-2-methylpropanenitrile, is prepared by the following reaction ... 

Figure 7.7 Fj versus fj for styrene (Mi)-methyl methacrylate (M2) copoly mers prepared by the mechanisms indicated. [From D. C. Pepper, Q. Revie London 8 88 (1954).]...

It is not the purpose of this book to discuss in detail the contributions of NMR spectroscopy to the determination of molecular structure. This is a specialized field in itself and a great deal has been written on the subject. In this section we shall consider only the application of NMR to the elucidation of stereoregularity in polymers. Numerous other applications of this powerful technique have also been made in polymer chemistry, including the study of positional and geometrical isomerism (Sec. 1.6), copolymers (Sec. 7.7), and helix-coil transitions (Sec. 1.11). We shall also make no attempt to compare the NMR spectra of various different polymers instead, we shall examine only the NMR spectra of different poly (methyl methacrylate) preparations to illustrate the capabilities of the method, using the first system that was investigated by this technique as the example. 

Figure 7.10 shows the 60-MHz spectra of poly (methyl methacrylate) prepared with different catalysts so that predominately isotactic, syndiotactic, and atactic products are formed. The three spectra in Fig. 7.10 are identified in terms of this predominant character. It is apparent that the spectra are quite different, especially in the range of 5 values between about 1 and 2 ppm. Since the atactic polymer has the least regular structure, we concentrate on the other two to make the assignment of the spectral features to the various protons. 

Fox and Schneckof carried out the free-radical polymerization of methyl methacrylate between -40 and 250 C. By analysis of the a-methyl peaks in the NMR spectra of the products, they determined the following values of a, the probability of an isotactic placement in the products prepared at the different temperatures ... 

The sedimentation and diffusion coefficients for three different preparations of poly(methyl methacrylate) were measuredf in /i-butyl chloride at 35.6 C (= 0) and in acetone at 20 C (> 0) and the following results were obtained ... 

Poly(acrylic acid) and Poly(methacrylic acid). Poly(acryHc acid) (8) (PAA) may be prepared by polymerization of the monomer with conventional free-radical initiators using the monomer either undiluted (36) (with cross-linker for superadsorber appHcations) or in aqueous solution. Photochemical polymerization (sensitized by benzoin) of methyl acrylate in ethanol solution at —78° C provides a syndiotactic form (37) that can be hydrolyzed to syndiotactic PAA. From academic studies, alkaline hydrolysis of the methyl ester requires a lower time than acid hydrolysis of the polymeric ester, and can lead to oxidative degradation of the polymer (38). Po1y(meth acrylic acid) (PMAA) (9) is prepared only by the direct polymerization of the acid monomer it is not readily obtained by the hydrolysis of methyl methacrylate. 

Emulsion Polymerization. Emulsion polymerization is the most important industrial method for the preparation of acryhc polymers. The principal markets for aqueous dispersion polymers made by emulsion polymerization of acryhc esters are the paint, paper, adhesives, textile, floor pohsh, and leather industries, where they are used principally as coatings or binders. Copolymers of either ethyl acrylate or butyl acrylate with methyl methacrylate are most common. 

Numerous recipes have been pubUshed, primarily ia the patent Hterature, that describe the preparation of acrylate and methacrylate homopolymer and copolymer dispersions (107,108). A typical process for the preparation of a 50% methyl methacrylate, 49% butyl acrylate, and 1% methacrylic acid terpolymer as an approximately 45% dispersion ia water begias with the foUowiag charges ... 

Suspension Polymerization. Suspension polymerisation yields polymer in the form of tiny beads, which ate primarily used as mol ding powders and ion-exchange resins. Most suspension polymers prepared as mol ding powders are poly(methyl methacrylate) copolymers containing up to 20% acrylate for reduced btittieness and improved processibiUty are also common. 

A number of methods such as ultrasonics (137), radiation (138), and chemical techniques (139—141), including the use of polymer radicals, polymer ions, and organometaUic initiators, have been used to prepare acrylonitrile block copolymers (142). Block comonomers include styrene, methyl acrylate, methyl methacrylate, vinyl chloride, vinyl acetate, 4-vinylpyridine, acryUc acid, and -butyl isocyanate. 

Most large-scale industrial methacrylate processes are designed to produce methyl methacrylate or methacryhc acid. In some instances, simple alkyl alcohols, eg, ethanol, butanol, and isobutyl alcohol, maybe substituted for methanol to yield the higher alkyl methacrylates. In practice, these higher alkyl methacrylates are usually prepared from methacryhc acid by direct esterification or transesterification of methyl methacrylate with the desired alcohol. 

Transesterification of methyl methacrylate with the appropriate alcohol is often the preferred method of preparing higher alkyl and functional methacrylates. The reaction is driven to completion by the use of excess methyl methacrylate and by removal of the methyl methacrylate—methanol a2eotrope. A variety of catalysts have been used, including acids and bases and transition-metal compounds such as dialkjitin oxides (57), titanium(IV) alkoxides (58), and zirconium acetoacetate (59). The use of the transition-metal catalysts allows reaction under nearly neutral conditions and is therefore more tolerant of sensitive functionality in the ester alcohol moiety. In addition, transition-metal catalysts often exhibit higher selectivities than acidic catalysts, particularly with respect to by-product ether formation. 

Chain transfer to solvent is an important factor in controlling the molecular weight of polymers prepared by this method. The chain-transfer constants for poly(methyl methacrylate) in various common solvents (C) and for various chain-transfer agents are Hsted in Table 10. 

A typical process for the preparation of an acryUc solution terpolymer of composition 27.5% 2-ethyIhexyl acrylate—41.3% methyl methacrylate—31.2% hydroxyethyl methacrylate begins with the following charges ... 

A typical process for the preparation of a poly(methyl methacrylate) suspension polymer involves charging a mixture of 24.64 parts of methyl methacrylate and 0.25 parts of benzoyl peroxide to a rapidly stirred, 30°C solution of 0.42 parts of disodium phosphate, 0.02 parts of monosodium phosphate, and 0.74 parts of Cyanomer A-370 (polyacrylamide resin) in 73.93 parts of distilled water. The reaction mixture is heated under nitrogen to 75°C and is maintained at this temperature for three hours. After being cooled to room temperature, the polymer beads are isolated by filtration, washed, and dried (69). 

MBS polymers are prepared by grafting methyl methacrylate and styrene onto a styrene—butadiene mbber in an emulsion process. The product is a two-phase polymer useful as an impact modifier for rigid poly(vinyl chloride). 

A review covers the preparation and properties of both MABS and MBS polymers (75). Literature is available on the grafting of methacrylates onto a wide variety of other substrates (76,77). Typical examples include the grafting of methyl methacrylate onto mbbers by a variety of methods chemical (78,79), photochemical (80), radiation (80,81), and mastication (82). Methyl methacrylate has been grafted onto such substrates as cellulose (83), poly(vinyl alcohol) (84), polyester fibers (85), polyethylene (86), poly(styrene) (87), poly(vinyl chloride) (88), and other alkyl methacrylates (89). 

Optics. Good optical properties and low thermal resistance make poly(methyl methacrylate) polymers well suited for use as plastic optical fibers. The manufacturing methods and optical properties of the fibers have been reviewed (124) (see Fiber optics). Methods for the preparation of Fresnel lenses and a Fresnel lens film have been reported (125,126). Compositions and methods for the industrial production of cast plastic eyeglass lenses are available (127). 

Interpenetrating networks of DMPPO and polymers such as polystyrene, polybutadiene, poly(urethane acrylate), and poly(methyl methacrylate) have been prepared by cross-linking solutions of DMPPO containing bromomethyl groups with ethylenediamine in the presence of the other polymer (68). 

Tetraneopentyltitanium [36945-13-8] Np Ti, forms from the reaction of TiCl and neopentyllithium ia hexane at —80° C ia modest yield only because of extensive reduction of Ti(IV). Tetranorbomyltitanium [36333-76-3] can be prepared similarly. When exposed to oxygen, (NpO)4Ti forms. If it is boiled ia ben2ene, it decomposes to neopentane. When dissolved ia monomers, eg, a-olefins or dienes, styrene, or methyl methacrylate, it initiates a slow polymerisation (211,212). Results from copolymerisation studies iadicate a radical mechanism (212). Ultraviolet light iacreases the rate of dissociation to... 

Block copolymers of vinyl acetate with methyl methacrylate, acryflc acid, acrylonitrile, and vinyl pyrrohdinone have been prepared by copolymeriza tion in viscous conditions, with solvents that are poor solvents for the vinyl acetate macroradical (123). Similarly, the copolymeriza tion of vinyl acetate with methyl methacrylate is enhanced by the solvents acetonitrile and acetone and is decreased by propanol (124). Copolymers of vinyl acetate containing cycHc functional groups in the polymer chain have been prepared by copolymeriza tion of vinyl acetate with A/,A/-diaIlylcyanamide and W,W-diaIl5lamine (125,126). 

Polymethacrylates. Poly(methyl methacrylate) [9011-14-7] is a thermoplastic. Itis the acryUc resin most used in building products, frequendy as a blend or copolymer with other materials to improve its properties. The monomer is polymerized either by bulk or suspension processes. Eor glazing material, its greatest use, only the bulk process is used. Sheets are prepared either by casting between glass plates or by extmsion of pellets through a sHt die. This second method is less expensive and more commonly used. Peroxide or azo initiators are used for the polymerization (see Methacrylic polymers). 

Acrylic Esters. A procedure has been described for preparation of higher esters from methyl acrylate that illustrates the use of an acid catalyst together with the removal of one of the products by azeotropic distillation (112). Another procedure for the preparation of butyl acrylate, secondary alkyl acrylates, and hydroxyalkyl acrylates using -toluenesulfonic acid as a catalyst has been described (113). Alurninumisopropoxide catalyzes the reaction of amino alcohols with methyl acrylate and methyl methacrylate. A review of the synthesis of acryhc esters by transesterification is given in Reference 114 (see... 

Acryloid and Plexigum. These were soft gummy products of interest as surface coatings rather than as mouldable plastics materials. About 1930 R. Hill in England and W. Bauer in Germany independently prepared poly(methyl methacrylate) and found it to be a rigid, transparent polymer, potentially useful as an aircraft glazing material. ... 

---