Free-radical acrylic homo-and copolymerization kinetics are reviewed, focusing on secondary reactions that impact the polymerization rate and polymer molecular weight (MW) under industrially-relevant synthesis conditions. Dependent on the monomer type (acrylate, methacrylate, styrene), mechanisms that must be considered include chain-end depropagation, monomer self-initiation, formation and reaction of midchain radicals, and incorporation of macromonomers formed by b-scission of midchain radicals. The relative importance of these reactions varies with temperature and, for copolymerization, monomer composition. A comprehensive treatment of these complexities has been completed for polymerizations conducted up to 180°C, but further work is required to extend the applicability of the model to even higher temperatures.
IntroductionThe production of low-density polyethylene and associated copolymers at 200-300°C and high pressure is perhaps the bestknown example of high-temperature free-radical polymerization (FRP). However, an increasing number of acrylic resins, produced from a mixture of monomers selected from the methacrylate, acrylate, and styrene families, are also manufactured under higher temperature conditions (>120°C) in homogeneous solution. Low-molecular-weight acrylic resins are the base polymer components for many automotive coatings due to their excellent resistance to chemicals, solvents, ultraviolet light, and abrasion, as well as their exterior durability after crosslinking on the surface of the vehicle [1]. High-temperature conditions are used to produce a variety of other materials for coatings, adhesives, and paints [2]. These conditions are chosen to increase production rates and to decrease (or eliminate) the solvent employed in the formulation while maintaining reasonable solution viscosity [2][3][4].While commercially advantageous, the high polymerization temperatures greatly promote the occurrence of secondary reactions that have a strong impact on polymerization rate and polymer MW, such as monomer self-initiation, chain depropagation, and the formation and subsequent reaction of midchain radicals and unsaturated polymer chains (macromonomers). These reactions occur in addition to the well-known and well-understood set of basic FRP mechanisms consisting of initiation, propagation, termination, and chain transfer [5,6]. This article provides an overview and summarizes recent experimental and modeling efforts by our group and other researchers to improve the understanding of these mechanisms. As most high-temperature acrylic polymerization processes involve multiple monomers, the complexities of including these reactions in copolymerization will also be addressed. An accurate treatment of high-temperature FRP kinetics is a critical component of larger-scale process models used to predict the influence of the operating conditions on reaction rate and polymer properties, guide the selection and optimization of standard operating conditions for existing and new polymer grades, and guide process ...