Patent GB-1093909-A (GB)
Title: Improvements in the production of thermoplastic polymeric materials
Inventor: GRIFFIN BRIAN PHILIP
IPC: C08F285/00
Filed: 1965-12-10
Abstract: A process for the production of thermoplastic polymeric materials comprises polymerizing by an aqueous granular polymerization process monomer material (A) consisting of methyl methacrylate and/or styrene together with 0 to 50% by weight of another copolymerizable monoethylenically unsaturated monomer in the presence of an aqueous dispersion (X) obtained by polymerizing monomer material (B) consisting of one or more C1 to C8 alkyl esters of acrylic acid, 0.01 to 10% by weight of one or more di- or polyethylenically unsaturated monomers and 0 to 50%, by weight of the acrylate ester, of another monoethylenically unsaturated monomer, said material (B) having been dispersed in an aqueous dispersion (Y) obtained by polymerizing monomer material (C) consisting of methyl methacrylate and/or styrene together with 0 to 50% of another monoethylenically unsaturated monomer, the proportions of materials (A), (B) and (C) being such that the final polymer contains 5 to 40% by weight of polymeric units derived from (B) and 95 to 60% of units derived from (A) and (C) taken together.  The di- or polyfunctional monomer in (B) is e.g. ethylene glycol dimethacrylate, di- or tri-ethylene glycol dimethacrylate, divinyl benzene, vinyl methacrylate, methylene dimethacrylate, allyl methacrylate, diallyl phthalate, diallyl maleate, allyl or methallyl acrylate, butadiene-1,3, isoprene or 2-chlorobutadiene.  Suitable optional comonomers for inclusion in (A), (B) or (C) are listed. In the examples, polymer dispersions are produced in three stages; in Stage I of Examples 1 to 6 a mixture of methyl methacrylate and ethyl acrylate is polymerized in an aqueous medium containing sodium polymethacrylate, a polyethylene oxide/polypropylene oxide condensate, Na2HPO4, a , a 1-azo-diisobutyronitrile and lauryl mercaptan: in Stage II a mixture of glycol dimethacrylate with n-butyl acrylate or ethyl acrylate, or with n-butyl acrylate and ethyl acrylate, 2-ethylhexyl acrylate, acrylonitrile or styrene, is added to the dispersion produced in Stage I, along with a , a 1-azo-dicyclohexane carbonitrile and more of the diisobutyronitrile catalyst, and polymerized: in Stage III more of the same monomer mixture, catalyst and mercaptan used in Stage I are added and polymerization is continued to yield the final dispersion.  In Examples 7 to 9 the Stage I and Stage III monomer mixtures are of methyl methacrylate and N-o-chlorophenyl maleimide, styrene or acrylonitrile and the Stage II mixture is of ethylene glycol dimethacrylate and n-butyl acrylate, whereas in Example 10 a styrene-acrylonitrile mixture is used in Stages I and III and acrylonitrile, glycol dimethacrylate and n-butyl acrylate in Stage II. In Examples 11 to 15 the Stages I and III mixtures are of n-butyl acrylate and methyl methacrylate and that of Stage II is as in Examples 7 to 9.  Methyl methacrylate and ethyl acrylate are used in Stages I and III of Examples 16 to 21 and glycol dimethacrylate, n-butyl acrylate and styrene in Stage II. The polymers produced may be injection or extrusion moulded to form e.g. wash basins, baths and sinks.