The Acrylics

The stoichiometric and the catalytic reactions occur simultaneously, but the catalytic reaction predominates. The process is started with stoichiometric amounts, but afterward, carbon monoxide, acetylene, and excess alcohol give most of the acrylate ester by the catalytic reaction. The nickel chloride is recovered and recycled to the nickel carbonyl synthesis step. The main by-product is ethyl propionate, which is difficult to separate from ethyl acrylate. However, by proper control of the feeds and reaction conditions, it is possible to keep the ethyl propionate content below 1%. Even so, this is significantly higher than the propionate content of the esters from the propylene oxidation route. 

Important side reactions are the formation of ether and addition of alcohol to the acrylate to give 3-alkoxypropionates. In addition to high raw material costs, this route is unattractive because of large amounts of sulfuric acid—ammonium sulfate wastes. 

Vapor-Phase Condensations of Acetic Acid or Esters with Formaldehyde. Addition of a methylol group to the a-carbon of acetic acid or esters, foUowed by dehydration, gives the acrylates. 

Acryhc acid and esters are stabilized with minimum amounts of inhibitors consistent with stabihty and safety. The acryhc monomers must be stable and there should be no polymer formation for prolonged periods with normal storage and shipping (4,106). The monomethyl ether of hydroquinone (MEHQ) is frequentiy used as inhibitor and low inhibitor grades of the acrylate monomers are available for bulk handling. MEHQ at 10—15 ppm is generally... 

Historically, the development of the acrylates proceeded slowly they first received serious attention from Otto Rohm. AcryUc acid (propenoic acid) was first prepared by the air oxidation of acrolein in 1843 (1,2). Methyl and ethyl acrylate were prepared in 1873, but were not observed to polymerize at that time (3). In 1880 poly(methyl acrylate) was reported by G. W. A. Kahlbaum, who noted that on dry distillation up to 320°C the polymer did not depolymerize (4). Rohm observed the remarkable properties of acryUc polymers while preparing for his doctoral dissertation in 1901 however, a quarter of a century elapsed before he was able to translate his observations into commercial reaUty. He obtained a U.S. patent on the sulfur vulcanization of acrylates in 1912 (5). Based on the continuing work in Rohm s laboratory, the first limited production of acrylates began in 1927 by the Rohm and Haas Company in Darmstadt, Germany (6). Use of this class of compounds has grown from that time to a total U.S. consumption in 1989 of approximately 400,000 metric tons. Total worldwide consumption is probably twice that. 

Mechanical and Thermal Properties. The first member of the acrylate series, poly(methyl acrylate), has fltde or no tack at room temperature it is a tough, mbbery, and moderately hard polymer. Poly(ethyl acrylate) is more mbberflke, considerably softer, and more extensible. Poly(butyl acrylate) is softer stiU, and much tackier. This information is quantitatively summarized in Table 2 (41). In the alkyl acrylate series, the softness increases through n-octy acrylate. As the chain length is increased beyond n-octy side-chain crystallization occurs and the materials become brittle (42) poly( -hexadecyl acrylate) is hard and waxlike at room temperature but is soft and tacky above its softening point. 

Solution Properties. Typically, if a polymer is soluble ia a solvent, it is soluble ia all proportions. As solvent evaporates from the solution, no phase separation or precipitation occurs. The solution viscosity iacreases continually until a coherent film is formed. The film is held together by molecular entanglements and secondary bonding forces. The solubiUty of the acrylate polymers is affected by the nature of the side group. Polymers that contain short side chaias are relatively polar and are soluble ia polar solvents such as ketones, esters, or ether alcohols. As the side chaia iacreases ia length the polymers are less polar and dissolve ia relatively nonpolar solvents, such as aromatic or aUphatic hydrocarbons. 

Analytical Methodsfor the Acrylic Monomers, CM-18, Rohm and Haas Co., Philadelphia, Pa. 

Carbon and Graphite Fibers. Carbon and graphite fibers (qv) are valued for their unique combination of extremely high modulus and very low specific gravity. Acrylic precursors are made by standard spinning conditions, except that increased stretch orientation is required to produce precursors with higher tenacity and modulus. The first commercially feasible process was developed at the Royal Aircraft Fstablishment (RAF) in collaboration with the acrylic fiber producer, Courtaulds (88). In the RAF process the acrylic precursor is converted to carbon fiber in a two-step process. The use of PAN as a carbon fiber precursor has been reviewed (89,90). 

Unlike most crystalline polymers, PVDF exhibits thermodynamic compatibiUty with other polymers (133). Blends of PVDF and poly(methyl methacrylate) (PMMA) are compatible over a wide range of blend composition (134,135). SoHd-state nmr studies showed that isotactic PMMA is more miscible with PVDF than atactic and syndiotactic PMMA (136). MiscibiUty of PVDF and poly(alkyl acrylates) depends on a specific interaction between PVDF and oxygen within the acrylate and the effect of this interaction is diminished as the hydrocarbon content of the ester is increased (137). Strong dipolar interactions are important to achieve miscibility with poly(vinyhdene fluoride) (138). PVDF blends are the object of many papers and patents specific blends of PVDF and acryflc copolymers have seen large commercial use. 

The Ts of methacryhc polymers may be regulated by the copolymerization of two or more monomers as illustrated in Figure 1. The approximate T value for the copolymer can be calculated from the weight fraction of each monomer type and the T (in K) of each homopolymer (15). Acrylates with low transition temperatures are frequently used as permanent plasticizers (qv) for methacrylates. Unlike plasticizer additives, once polymerized into the polymer chain, the acrylate cannot migrate, volatilize, or be extracted from the polymer. 

X-Ray Diffraction. Because of the rapid advancement of computer technology (qv), this technique has become almost routine and the stmctures of moderately complex molecules can be estabUshed sometimes in as Htde as 24 hours. An example illustrating the method is offered by Reference 24. The reaction of the acrylate (20) with phenyldiazo derivatives results in the formation of pyrazoline (21). The stereochemistry of the substituents and the conformation of the ring can only be estabUshed by single crystal x-ray diffraction. 

An extensive investigation of the dilute solution properties of several acrylate copolymers has been reported (80). The behavior is typical of flexible-backbone vinyl polymers. The length of the acrylate ester side chain has Httle effect on properties. 

The most effective and widely used dispersants are low molecular weight anionic polymers. Dispersion technology has advanced to the point at which polymers are designed for specific classes of foulants or for a broad spectmm of materials. Acrylate-based polymers are widely used as dispersants. They have advanced from simple homopolymers of acryflc acid to more advanced copolymers and terpolymers. The performance characteristics of the acrylate polymers are a function of their molecular weight and stmcture, along with the types of monomeric units incorporated into the polymer backbone. 

Interpenetrating networks have been made by co-curing polychloroprene with copolymers of 1-chloro-1,3-butadiene [627-22-5]. The 1-chloro-1,3-butadiene serves as a cure site monomer, providing a cure site similar to that already in polychloroprene. The butadiene copolymer with 1-chloro-1,3-butadiene (44) and an octyl acrylate copolymer (45) improved the low temperature brittieness of polychloroprene. The acrylate also improved oil resistance and heat resistance. 

The methanol-methyl acrylate azeotrope contains about 45% methyl acrylate, which can be recovered by washing out the methanol with a large volume of water or brine the acrylate is purified by, drying and distilling. An inhibitor, such as hydro-quinone, should always be added to any acrylic ester before attempting to distil it, and, unless it is stored in a refrigerator, the distilled ester should not be kept more than a few hours without the addition of a small amount (0.1-1.0%) of an inhibitor. 

Degenerate Explosion it was a free radical autocatalytic process and control was difficult, but manageable. The main disadvantage was that it produced as much or more acrolein as propylene oxide. Because no market existed for acrolein at that time, the project was abandoned. Within two years, the acrylic market developed and a new project was initiated to make acrolein and acrylic acid by vapor-phase catalytic oxidation of propylene. 

Skipping the pilot-plant saved 1 to 2 million dollars and made it possible for the company to enter the acrylic market a full year ahead of the competition. It was assumed that the savings would be enough to pay for any changes in the production unit that might be needed. 

Subsequently, several other companies have entered the acrylic rubber market (e.g. Thiokol, American Cyanamid, Goodyear, Polymer Corporation and US Rubber) and this has led to many technical developments. These may be categorised into the three main areas ... 

Over the years many blends of polyurethanes with other polymers have been prepared. One recent example is the blending of polyurethane intermediates with methyl methacrylate monomer and some unsaturated polyester resin. With a suitable balance of catalysts and initiators, addition and rearrangement reactions occur simultaneously but independently to give interpenetrating polymer networks. The use of the acrylic monomer lowers cost and viscosity whilst blends with 20% (MMA + polyester) have a superior impact strength. 

Table 2 indicates that only the acrylic foam tapes comjjete in adhesive strength comparison in any realistic sense with the conventional adhesives. 

The humidity requirement is probably most significant for polar or hydrophilic adhesives, for example,. some of the acrylate adhesives. 

Acrylics are some of the most common and most versatile materials used in the PSA industry. Although the basic monomers and some of the acrylic polymers have been known for about a century, their commercial application as pressure sensitive adhesives did not happen until after the Second World War. 

Despite these early successes in the commercialization of acrylic polymers, no acrylic PSAs were manufactured on a larger scale until many years later. One of the primary reasons for the initial commercial failure of the acrylic PSAs was their lack of cohesive strength. Unlike the higher Tg, plastic-like polymers obtained from monomers like methylmethacrylate, polymers synthesized from alkyl acrylates typically formed sticky, cold-flowing materials with little if any utility. 

Acrylate polymers also have fully saturated polymer backbones free of any heteroatoms in the main chain. This makes the polymers highly resistant to oxidation, photo-degradation and chemical attack. The acrylate groups are esters, which could be hydrolyzed under severe conditions. However, the hydrophobic nature of most acrylic polymers minimizes the risk for hydrolysis and, even if this reaction happened to some extent, the polymer backbone would still be intact. Other desirable acrylate properties include the following ... 

As shown in Table 3, the glass transition temperature of the acrylate homopolymers is very much dependent on the nature of the alcohol that was used to make the acrylate ester. Typically, the Tg is the lowest when the number of carbons in the alkyl group (R in the formula above) is about 8-12. 

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