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Acrylic Plastics

Introduction
CH3 CH3
Polymerization
n CH2=C CH2-C
n
COOCH3 COOCH3

 The first acrylic based polymers were introduced in 1873.


 In 1901 Mr. Otto Rohm presented his dissertation on
acrylic polymers and in 1927 Rohm and Haas produced
PMMA for use in Lacquers.
 In early 30’s Hill prepared PMMA .
 In 1932, Crawford developed cheap monomer
 In 1933 acrylic based products both sheet and articles
were commercialized.
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Acrylic Plastics

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Preparation of Monomer
- Acetone reacts with Hydrogen cyanide to give
acetocynohydrin. Then it reacts with 98% H2SO4 in a
cooled hydrolysis to give methacrylate amide sulphate
which reacts with methanol to form methyl methacrylate.

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Polymerization
Bulk Polymerization
 To prepare a prepolymer, the monomer (free from
inhibitor) is heated for 8 min. at 90°C with 0.5% of
benzoyl peroxide initiator and then cooled to room
temperature.
 Plasticizer, colourant or U.V. light absorber may be
incorporated at this stage. Resultant syrup is stored in
refrigerator.

 Acrylic sheet is prepared by pouring syrup into the casting


cells.

 Filled cells are passed through a heating tunnel for about


16hours at 40°C (sheet). Polymerization occurs slowly.

 After 15 hours, cell is kept at 97°C for half an hour and


sheet is then cooled and removed from cells.
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Suspension polymerization
Polymer
Monomer

Water Polymerization Stripping Centrifuging Drying


Vessel
Protective
Collides

Monomer soluble
free radical initiator

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Structure Property Relationship
CH3
CH2-C
n
COOCH3

 Due to α-Carbon atom commercial PMMA is hard,


transparent, amorphous material.
 α-Carbon atom restricts chain flexibility leading to higher
Tg than PE i.e104°C.
 As polymer is polar in nature, it does not have
electrical insulation properties comparable with
polyethylene.
 Its is soluble in MMA, toluene, trichloroethylene,
chloroform and ethyl acetate.

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Properties of
Polymethyl methacrylate

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General Properties

- It is hard, rigid and amorphous transparent


material.
- It is having good weathering resistance.
- As it is polar thermoplastic material, it’s
mechanical, electrical and other properties are
strongly dependent on temperature, testing rate and
humidity.
- It is somewhat tougher than Polystyrene but less
tougher than Cellulose Acetate and Acrylonitrile
Butadiene Styrene Copolymer.

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Additives
 In general Di butyl phthalate is used as a
plasticizer in the quantity of 5% which will improve
melt flow.

 In order to improve light stability, phenyl sallicilate,


2–4–dihydroxy–benzo–phenone and methyl
sallicilate are used.

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Processing Considerations
 The polymer absorbs moisture upto 0.3%, hence predrying
is required before processing and care must be taken with
reground.

 Melt viscosity is higher which needs high injection


pressure than polystyrene.

 The material is amorphous and the moulding shrinkage is


low.

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Processing Techniques
Injection Moulding

Typical Injection moulding conditions are

 Recommended processing temperatures ranges between


200 to 240°C .
 Recommended injection pressures in the range of 150-
175 MPa.
 Recommended mould temperatures are in the range of 21
to 60°C.

A cold mould could produce hazy and stress parts.

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Thermoforming

- PMMA can be formed by vacuum forming


when it is heated above the Tg of the polymer .
- The formed shape will recover about 90% of the
deformation.
- Typical forming temperatures are in the
range of 150 to 190°C.
- Parts should be cooled to at least 66°C before
they are removed from the mold.

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Trade names
Rohm - Acrifix
Mitsubishi, Japan, -Acrypane
Dupont, US - Corian
Asahi chemical, Japan -Delmer
Sumitomo chemical , Japan -Sumiplex
British Vita, UK - Unilok

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Applications
Automotive
 In automobile industry acrylics are widely used in production
of mirrors, wind shields, reflectors, rear lamp housing, head
light covers, display signs, instrument panels, electrical parts
etc.

Optical
 Use of acrylics in optical field has gain momentum in
producing optical lenses, spectacle lenses, video and TV
cameras, watch and sight glasses.

Appliances
 Different articles like water jugs, boxes, ice buckets, fruit
bowls, handle and knobs, lighting fixtures, refrigerators
drawers etc are manufactured from acrylics.
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Aircraft
 In aircraft industry the use of acrylics are in displays,
window glasses, level indicators, meter cases, food service
trays, tumblers, bathroom accessories and interiors etc.

Medical
 Acrylics are widely used in Medical sector for
manufacturing disposable syringes, medical trays,
laboratory fixtures, dental disposables, gums, artificial
body parts, baby incubators, medical instruments etc.

Building
 In building industry the commonly used parts from acrylics
are green house glazing, safety glazing, lamp housing, roof
covering, light pipes.

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Applications

Vegetable tray Sign boards

Dental application

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