Batch cell bulk polymerization

1. The mold for producing sheets is assembled from two plates of polished
glass separated by a flexible "window-frame" spacer. The spacer sits along
the outer perimeter of the surface of the glass plates and forms a sealed
cavity between the plates. The fact that the spacer is flexible allows the
mold cavity to shrink during the polymerization process to compensate for
the volume contraction of the material as the reaction goes from individual
molecules to linked polymers. In some production applications, polished
metal plates are used instead of glass. Several plates may be stacked on
top of each other with the upper surface of one plate becoming the bottom
surface of the next higher mold cavity. The plates and spacers are clamped
together with spring clamps.

2. An open comer of each mold cavity is filled with a pre-measured liquid

syrup of methyl methacrylate monomer and catalyst. In some cases, a
methyl methacrylate prepolymer is also added. A prepolymer is a material
with partially formed polymer chains used to further help the polymerization
process. The liquid syrup flows throughout the mold cavity to fill it.

3. The mold is then sealed and heat may be applied to help the catalyst start
the reaction.

4. As the reaction proceeds, it may generate significant heat by itself. This

heat is fanned off in air ovens or by placing the molds in a water bath. A
programmed temperature cycle is followed to ensure proper cure time
without additional vaporization of the monomer solution. This also prevents
bubbles from forming. Thinner sheets may cure in 10 to 12 hours, but
thicker sheets may require several days.

5. When the plastic is cured, the molds are cooled and opened. The glass or
metal plates are cleaned and reassembled for the next batch.
 6. The plastic sheets are either used as is or are annealed by heating them to
284-302F (140-150C) for several hours to reduce any residual stresses in
the material that might cause warping or other dimensional instabilities.

7. Any excess material, or flash, is trimmed off the edges, and masking paper
or plastic film is applied to the surface of the finished sheets for protection
during handling and shipping. The paper or film is often marked with the
material's brand name, size, and handling instructions. Conformance with
applicable safety or building code standards is also noted.

Continuous bulk polymerization

1. The continuous process is similar to the batch cell process, but because
the sheets are thinner and smaller, the process times are much shorter.
The syrup of monomer and catalyst is introduced at one end of a set of
horizontal stainless steel belts running parallel, one above the other. The
distance between the belts determines the thickness of the sheet to be
formed.

2. The belts hold the reacting monomer and catalyst syrup between them and
move it through a series of heating and cooling zones according to a
programmed temperature cycle to cure the material.

3. Electric heaters or hot air may then anneal the material as it comes out of
the end of the belts.

4. The sheets are cut to size and masking paper or plastic film is applied.