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Polymethyl methacrylate powder, PMMA for short, is a kind of macromolecular polymer, which is dissolved in organic solvents such as carbon tetrachloride, benzene, toluene, dichloroethane, trichloromethane and acetone. Good optical, insulating, processing and weather resistance. Also known as acrylic or plexiglass, it has the advantages of high transparency, low price, easy machining, etc., and is often used as a substitute for glass. It is applicable to parts with certain strength and transparency, such as shock proof, explosion-proof and easy to observe. It is used to manufacture window glass, optical lens, camera, equipment label, transparent model, transparent pipe, taillight cover, instrument, instrument panel and shell, electrical insulation parts of aircraft, automobile, ship, etc. It can also be used for stationery, daily necessities and other decoration.
Polymethyl methacrylate (PMMA), commonly known as organic glass or acrylic, is a polymer material prepared by polymerization reaction using methyl methacrylate (MMA) as the monomer. Its molecular chain structure endows it with unique physical and chemical properties, including high transparency, low density, excellent mechanical properties, weather resistance, and processability, making it one of the most widely used polymer materials across various fields.
1. Lens and optical components
PMMA has a transmittance of up to 92% (ordinary light) to 76% (ultraviolet light), a moderate refractive index (about 1.49), and low dispersion, making it the preferred material for optical lenses. Its applications cover:
Glasses lenses: Lightweight design reduces wearing burden and has better impact resistance than traditional glass lenses.
Camera and microscope lens: High precision optical surfaces are achieved through precision injection molding or polishing processes to meet imaging requirements.
Laser light guiding system: using the principle of total reflection to design fiber optic sleeves for medical endoscopes or industrial testing equipment.
2. Display technology support
LCD/LED light guide plate: Polymethyl methacrylate powder converts point light sources into uniform surface light sources through microstructure carving, and is widely used in backlight modules for televisions, mobile phones, and computer displays. For example, a certain brand's 55 inch TV light guide plate has a thickness of only 2mm and a light transmittance of over 90%.
OLED packaging substrate: Its high transparency and low water absorption (<0.3%) can effectively protect the organic light-emitting layer and extend the device life.
1. Lighting and structural materials
Skylight and curtain wall: PMMA panels replace traditional glass, reducing weight by 50% and increasing impact resistance by 7-18 times. A commercial complex in Shanghai adopts 8mm thick PMMA skylights, achieving a 30% increase in natural light utilization and reducing building loads.
Sound barrier: achieved noise reduction of 15-20 decibels through a multi-layer composite structure (PMMA+PC+sound-absorbing cotton), widely used in highways and urban overpasses.
2. Decoration and Art Installation
Advertising lightbox and signage: PMMA boards are laser cut or hot bent to achieve high brightness and low energy consumption visual effects, combined with LED light sources. A flagship store of an international brand uses 3D printed PMMA light boxes, which reduce energy consumption by 60% compared to traditional neon lights.
Art sculpture and installation: Its easy to dye characteristics (can be adjusted to more than 1000 colors) and plasticity have become a medium for contemporary artists to create. For example, a public art project uses transparent PMMA to construct a suspended cube and achieves dynamic light and shadow effects through internal light projection.
1. Implantable medical devices
Artificial joints and bone cement: By introducing bioactive groups through copolymerization modification, the compatibility between PMMA based composite materials and human tissues is significantly improved. A certain orthopedic implant uses PMMA/hydroxyapatite (HA) composite material, which reduces postoperative bone integration time by 40%.
Dental restoration material: PMMA molding material made by suspension polymerization is used for denture abutments. Its hardness (Shore D 85-90) and elastic modulus (2.5-3.0 GPa) are close to natural tooth enamel, and the wearing comfort is improved.
2. Medical equipment components
Endoscope light guide tube: The diameter of Polymethyl methacrylate powder fiber sleeve can be as small as 0.5mm, and the bending radius can reach 10 times the diameter, meeting the needs of minimally invasive surgery.
Blood storage containers and dialysis membranes: Their chemical stability (acid and alkali resistance, pH 2-11) and low protein adsorption characteristics ensure the activity of blood components.
1. Transparent and semi transparent components
Lamp cover: The PMMA injection molded tail lamp cover has a light transmittance of 90% and meets the SAE J576 standard for impact resistance. After a certain vehicle model adopts PMMA lampshade, the weight of the lamp group is reduced by 35% and the energy consumption is reduced by 15%.
Instrument panel and interior parts: Through surface hard coating treatment (hardness up to 3H), the wear resistance of PMMA interior parts is increased by 5 times, meeting the long-term use needs of automotive interiors.
2. Application of new energy
Battery pack shell: Modified PMMA (with added glass fiber) has improved temperature resistance to 120 ℃ and flame retardant rating to UL94 V-0. A certain electric vehicle battery pack uses PMMA/PC alloy shell, which reduces weight by 40% compared to the metal solution.
1. High frequency insulation materials
5G base station antenna cover: dielectric constant of PMMA (ε)= 3.2@1GHz )The tangent of the loss angle (tan δ=0.0002) meets the high-frequency communication requirements. After a certain base station adopts a PMMA antenna cover, the signal attenuation is reduced by 2dB.
Flexible circuit substrate: PMMA film (thickness 10-50 μ m) prepared by solution casting method has a bending resistance of up to 100000 times and is used as a support layer for foldable screens in wearable devices.
2. Encapsulation and Protection
LED light source diffuser: PMMA microstructure surface (prism or dot) achieves uniform distribution of light. After adopting PMMA diffuser cover in a certain street lamp project, the illuminance uniformity has been improved to 0.7.
Electronic component packaging: Epoxy modified PMMA (temperature resistant to 150 ℃) is used for sensor packaging, with a protection level of IP67.
1. Transparent structural components
Aircraft cockpit cover: Stretch treated PMMA (tensile strength ≥ 70MPa) is used for light aircraft cockpit covers, which reduces weight by 20% compared to polycarbonate (PC) solutions and meets bird strike resistance standards (FAR 25.571).
Spacecraft observation window: A certain satellite uses multi-layer PMMA/polyimide composite windows, with a radiation dose resistance of 10 ⁶ Gy and a transmittance attenuation of<5%.
2. Lightweight interior design
Cabin interior decorative panel: PMMA/carbon fiber composite material with a density of only 1.2g/cm ³, meets FAA combustion performance requirements (OSU 65/65), and is used for aircraft cabin wall panels.
Innovative Applications of Daily Necessities and Industrial Products
1. Consumer electronics products
Mobile phone protective case: The transparent polymethyl methacrylate powder case combines anti drop and aesthetic effects through dual color injection molding technology. A certain brand model uses PMMA+TPU composite case, and the drop test has passed a height of 2 meters.
Stationery and office supplies: PMMA pen holder has a surface hardness of 2H and better wear resistance than ABS plastic. A high-end pen brand uses PMMA pen holder, which extends its service life by three times.
2. Industrial products
Video disc substrate: PMMA disc (thickness 1.2mm) with a storage density of 25GB/layer. A certain archival grade disc uses PMMA substrate with a shelf life of over 50 years.
Shadow light diffuser: Through micro nano structure processing (such as grating or Fresnel lens), PMMA diffuser achieves precise light control. After a theater stage light adopts PMMA diffuser, the uniformity of the light spot is improved to 90%.
At present, the industrial production methods of MMA mainly include acetone cyanohydrin process (ACH process), improved acetone cyanohydrin process (MGC process), Evonik ACH process (Aveneer process), isobutylene process, ethylene process (BASF process and q.MMA process of improved BASF process, among which acetone cyanohydrin process and isobutylene process are the main production methods.
1. Acetone cyanohydrin method (ACH method)
1) Traditional ACH method: The traditional ACH method uses acetone, a by-product of phenol, and hydrocyanic acid, a by-product of acrylonitrile, as raw materials, to generate ACH, which is then heated in concentrated sulfuric acid to generate methacrylamide sulfate, and then esterified with methanol to generate MMA. The process effectively utilized the by-products of petrochemical industry, and the yield was more than 97%, whether calculated by acetone or hydrocyanic acid. However, a large amount of wastewater and by-products of ammonium bisulfate with low market value are generated in the process. Every 1 t of polymethyl methacrylate is generated, 1.2 t of ammonium bisulfate is by-product, which increases the subsequent treatment cost and causes serious pollution. In addition, the process unit must adopt acid resistant equipment, and the raw material hydrocyanic acid is highly toxic. The construction of hydrocyanic acid synthesis unit is restricted by technical raw materials, environmental protection and other conditions, and strict protective measures are required during storage, transportation and use.
2) Improved acetone cyanohydrin method (MGC method): Mitsubishi Gas Company of Japan has developed an improved ACH route, named MCG route, which discards the use of sulfuric acid and realizes the recycling of hydrocyanic acid. The first step of MGC method is the same as that of traditional ACH method. Acetone reacts with hydrocyanic acid to generate ACH. In the second step, ACH is hydrated to form a. Hydroxy isobutyramide reacts with formic acid to generate methyl hydroxyisobutyrate and formamide. Methyl hydroxyisobutyrate is dehydrated to generate MMA, while formamide is decomposed into water and hydrocyanic acid, and most hydrocyanic acid is recycled to ensure the supply of raw materials. Although this method does not produce ammonium bisulfate as a by-product, the overall yield of polymethyl methacrylate is about 93%.
2. Isobutylene method
In 1982, Mitsubishi Rensi and Japan polymethyl methacrylate powder Monomer Company used isobutylene/tert butyl alcohol (TBA) as raw materials. In 1982, Mitsubishi Liyang and other companies developed the three-step isobutylene MMA process and industrialized it. Using isobutylene as raw material, the first step was to oxidize to methacrolein, and the second step was to oxidize to methacrylic acid. The third step is esterification of methacrylic acid and methanol to produce MMA.
In 1998, Asahi Kasei Company of Japan industrialized a two-step isobutylene MMA plant. Using isobutylene as raw material, the first step was to oxidize it to methacrolein, and the second step was to esterify methacrolein with methanol and air to form polymethyl methacrylateThrough the MAA step, the new process effectively avoids side reactions such as MAA polymerization, simplifies the process, reduces energy consumption, thus greatly reducing investment costs and operating costs, making the isobutylene raw material route more competitive. The advantage of isobutene method is that it makes full use of c4 fraction rich in raw materials: the atom utilization rate is high (73%), which is 25% higher than the traditional ACH method, and 27% of the atoms that are not used generate water molecules, which avoids the generation of waste acid and equipment corrosion, but the disadvantage is that the yield is low.
It is often used as a substitute for glass. The properties of the material are as follows:
physical property
1. The density of PMMA is lower than that of glass: the density of PMMA is about 1.15-1.19g/cm3, half of that of glass (2.40-2.80g/cm3), and 43% of that of aluminum (a light metal).
2. The mechanical strength of polymethyl methacrylate is high: the relative molecular weight of PMMA is about 2 million, which is a long chain polymer, and the chain forming the molecule is very soft. Therefore, the strength of PMMA is relatively high, and its tensile and impact resistance is 7 to 18 times higher than that of ordinary glass. There is a kind of plexiglass that has been heated and stretched. The molecular chains in it are arranged in a very orderly way, so that the toughness of the material is significantly improved. Nails are used to drive into the plexiglass. Even if the nails penetrate, no cracks will occur. This kind of plexiglass will not break into pieces after being punctured by bullets. Therefore, the stretched PMMA can be used as bulletproof glass and also as the cockpit cover of military aircraft.
3. The melting point of polymethyl methacrylate is low, much lower than the high temperature of glass, which is about 1000 ℃.
4. High light transmittance of PMMA
(1) Visible light: PMMA is the best polymer transparent material at present, with a light transmittance of 92%, which is higher than that of glass.
(2) Ultraviolet light: quartz can completely penetrate ultraviolet light, but the price is high. Ordinary glass can only penetrate 0.6% ultraviolet light. PMMA can effectively filter ultraviolet light with wavelength less than 300nm, but the filtering effect is poor between 300nm and 400nm. Some manufacturers have coated the PMMA surface to increase the effect and property of filtering 300nm to 400nm ultraviolet light. On the other hand, compared with polycarbonate, polymethyl methacrylate has better stability when exposed to ultraviolet light
(3) Infrared ray: PMMA allows infrared ray (IR) with wavelength less than 2800nm to pass through. IR with longer wavelength can be basically blocked when it is less than 25000 nm. There is a special colored PMMA, which can let IR of specific wavelength pass through and block visible light (applied to remote control or thermal sensing, etc.).
(4) The glass transition temperature of polymethyl methacrylate is about 105 ° C.
chemical property
Because of its large branch chain and high viscosity of polymethyl methacrylate, the processing speed is relatively slow when using the thermal processing method. The plexiglass can not only be cut with a lathe and drilled with a drilling machine, but also be bonded into various shapes with acetone, chloroform, etc. It can also be processed into various products, ranging from airplane cabin covers to dentures and dentures, by plastic molding methods such as blow molding, injection, extrusion, etc.
Cyanoacrylate, dichloromethane or chloroform can slightly dissolve organic glass, and then two pieces of organic glass can be firmly bonded together.
The production of 1 kg of polymethyl methacrylate powder requires about 2 kg of oil. In the presence of oxygen, PMMA starts to burn at 458 ° C. After burning, it generates carbon dioxide, water, carbon monoxide and some low molecular compounds, including formaldehyde.
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