WO2016040014A1

WO2016040014A1 - Solution polymers including one or more 1,1-disubstituted alkene compounds, solution polymerization methods, and polymer compositions

Info

Publication number: WO2016040014A1
Application number: PCT/US2015/047466
Authority: WO
Inventors: Aniruddha S. PALSULE; Alexander R. Holzer; Peter R. Stevenson; Kshitij K. Parab; Jeffrey M. Sullivan
Original assignee: Sirrus, Inc.
Priority date: 2014-09-08
Filing date: 2015-08-28
Publication date: 2016-03-17
Also published as: EP3191533B1; EP3191530A4; JP2020002369A; US20170253675A1; US9969819B2; CN111825785A; WO2016040261A1; CN107075037B; CN107075223A; EP3191530A1; EP3191546A1; US9676875B2; EP3786199A1; EP3191533A4; EP3191546A4; EP3683267A1; JP2020117721A; JP6585163B2; CN107075223B; JP2017527667A

Abstract

The present teachings show that it is possible to anionically polymerize 1,1-disubstituted alkene compounds in a solution (for example using one or more solvents), Polymerization of 1,1-disubstituted alkene compounds in an solution provides opportunities to better control the polymerization compared with bulk polymerization. The solution polymerization techniques can be employed for preparing homopolymers, copolymers (e.g., random copolymers), and block copolymers.

Description

SOLUTION POLYMERS INCLUDING ONE OR MORE 1 , 1 -DiSUBSTiTUTED ALKENE COMPOUNDS, SOLUTION POLYMERIZATION METHODS, AND POLYMER

COMPOSITIONS

CLAIM OF PRIORITY

[01 j The present application claims priorit to U .S. Patent Application Numbers 14/810,741 filed on July 23, 2015 and 147789,178 filed on July 1 , 2015; and U .S. Provisional Patent Applications Numbers $2/186,479 filed on June 30, 2015, 62/182,076 filed on June 19, 2015, 62/047,283 filed on September 8, 2014, and 62/047,328 filed on September 8, 2014; a!i incorporated herein fay reference in their entirety.

FIELD

[02] The teachings herein are directed at poiymers including one or more 1 ,1 - disubstituted alkene compounds having a hydrocarbyi group bonded to the carbonyi groups through a direct bond or through an oxygen atom, methods for preparing the polymers in solution, compositions inciuding the polymers, and the use of the poiymers. The poiymers may be homopoiymers consisting essentialy of (e.g., about 99 weight percent or more) or entirely of a single monomer or may be copolymers including two or more monomers (e.g ., a random copolymer or a block copolymer having a p!uraiity of polymer blocks). The polymer preferably is prepared by anionic polymerization of one or more reactive l .l-disubstituted alkene monomers in solution.

BACKGROUND

[03] Polymerization of 1 , 1 -dtsubstituted alkene compounds are typically performed in bulk state, and frequently in situ, such as when monomer is placed between two substrates to be adhered. The resulting polymerization process may be difficult to control resulting in variable performance or mechanical properties. For exampie, the polymerization process may be characterized by one or more spikes in temperature during the polymerization process, such as by an increase in temperature of about 15 "C or more, about 30 "C or more, or even about 45 "C or more (e.g., during a polymerization reaction). Such an increase in temperature may occur in a short time period (e.g., less than 10 minutes, less than 3 minutes, or even less than 1 minute). Typically, the resulting polymer may be characterized by one or more of ihe following: a generall high level of branching, a high poSydispersity index, a high concentration of non-polymer reaction products, a high concentratio of monomers and/or oligomers, or a generally high viscosity. For example, when polymerized in bulk, the resulting polymer may have a high viscosity that makes further processing, handling, or polymerization difficult.

[043 As used herein, bulk polymerization refers to the polymerization of a polymerizabie composition including one or more monomers where the concentration of the one or more monomers is about 80 weight percent or more, preferably about 90 weight percent or more {e.g.. about 100 weight percent), based on the tota! weight of the compounds in the po!ymerizab!e composition that are liquid at room temperature. These polymerizations typically a!so require an input of energy either in the form of heat or radiation to initiate polymerization.

[OS] Free radical polymerization of dialkyl methylene malonate monomers using heat, UV tight and peroxide is described in U.S. Patent No, 2,330,033 and 2,403,791, both incorporated herein by reference, in these patents, the monomer was prepared using traditional methods which results in low purity monomer. The polymer examples in these patents are all prepared via bulk polymerization. One would therefore not expect to be able to control polymer properties, such as molecular weight and molecular weight distribution, [06] However, while earlier methods for producing certain methylene maionates have been known in the art, these prior methods suffer significant deficiencies that preclude their use in obtaining commercially viable monomers. Such deficiencies include unwanted polymerization of the monomers during synthesis (e.g., formation of polymers or oligomers or alternative complexes), formation of undesirable side products {e.g., kefals or other latent acid-forming species which impede rapid polymerization), degradation of the product, insufficient and/or low yields, and ineffective and/or poorly functioning monomer product (e.g., poor adhesive characteristics, stability, or other functional characteristics}, among other problems. The overall poorer yield, quality, and chemical performance of the monomer products formed by prior methods have impinged on their practical use in the production of the above commercial and industrial products,

[07] Polymerization of 1 ,1-disubstifuted alkene compounds using anionic polymerization processes are useful in the bulk polymerization of 1 , 1 ^(substituted alkene compounds and processes which can operate at or near ambient conditions {starting conditions) have been disclosed. Such anionic bulk polymerizations may be initiated using a wide range of initiators, and may even be initiated by contact with certain substrates. Other bulk polymerization reactions may be initiated by UV light. However, as discussed above, the bulk polymerization may limit the ability to control the structure of the polymer molecules and/or to be able to easily handle the resulting polymer composition or product. These difficulties in bulk polymerization may be particularly pronounced when manufacturing large quantities of polymer, where heat transport issues may occur, especially when there may be shear heat generated by the flow of the high viscosity polymer and/or heat emitted due to the inherent exothermic nature of the polymerization.

[08] Bulk polymerization of 1 ,1 -disubstituted alkene compounds also present a challenge when attempting to control the structure of the polymer by including one or more comonomers. For example, the high viscosity of the intermediate polymer may present difficulties in preparing a block copolymer (such as by sequential addition of a first monomer system followed by a second monomer system into a reaction vessel). Other problems may arise when attempting to control the structure of a random copolymer, where the reaction rates of the different monomers differ so thai the monomers are not uniformly distributed along the length of the potymer molecular, For example, copolymers including one or more 1 ,1-disubstituted aikene compounds prepared by bulk polymerization are typically expected to have a generally blocky sequence distribution and/or result in polymer molecules having a broad distribution of monomer compositions. As used herein, a copolymer having a generally blocky sequence distribution of monomers may be characterized as having a blockiness index of about 0.7 or less, about 0.8 or less or about 0.5 or less, or about 0.4 or less.

109] Although solution polymerization processes have been employed in free radical polymerization process to better control the polymer architecture, such processes have not generally been employed in anionic polymerization of 1 ,1-disubstituted a!kenes.

[10] When a solution polymerization system is employed with anionic polymerization methods, sub-ambient temperatures (e.g., less than 10 °C, less than 0 °C, or less than -20 "C are typically required to control the reaction. As such, in solution polymerization systems it may be necessary to use a cooling systems and/or insulation for achieving and/or maintain such a low reaction temperature.

[ j Additional difficulties in polymerization of 1 ,1 -disubstituted aikene compound arise from the possibility of the anionic group of the growing polymer reacting with an acid thereby terminating the reaction. Therefore, one vvou!d avoid using an acid in polymerizing 1 ,1- disubstituted aikene compounds using anionic polymerization.

[12] Prior attempts at anionic polymerization processes (e.g., bulk polymerization processes} for 1 ,1-disubstituted aikene compounds generally have had one or more of the foliowing drawbacks: (1 ) requirement thai the systems have Sow polymer concentrations; (2) have lacked reproducibility for controlling molecular weight distribution, or (3) have undesirable reactant by-products.

[13] There is a need for polymerization methods, systems, and resulting polymer compositions or products that a!iow for improved control of one or more of the following properties of a polymer containing one or more 1 ,1-disubstituted aiken compounds: the weight average molecular weight, the number average molecular weight, the poiydtsperstty index, the zero-shear viscosity of the polyme (e.g., at one or mor temperatures of at least about 20 °C above the melting temperature of the polymer), the viscosity of the polymer system (e.g., the bulk polymer or the polymer solution) at room temperature, the sequence distribution of monomers in a random copolymer, or having at least two different polymer blocks covaiently bonded {e.g., each containing one or more 1 ,1-disubstituted aikene compounds). There is also a need tor polymerization process which can be sca!ed-up (e.g., to a reactor of about 20 liters or more, or having a throughput of about 10 kg of po!ymer per hour or more. There is also a need for processes that resuft in a solution containing the polymer. Such solutions may be useful for applications such as paints, coatings, finishes, polishes, and adhesives. For example, there may h a need for process and polymer systems that result in a solution having a controlled viscosity and/or polymer concentration. SUMMARY

[14] One aspect of the disclosure Is directed at a process comprising the steps of: mixing two or more monomers (including a first monomer that is a 1 /1 -disubstituted alkene compound, and a second monomer different from the first monomer) and a solvent; adding an activator; reacting the activator with the one of the two or more monomers (e.g., with the first monomer, or with the second monomer) for initiating the anionic polymerization of the two or more monomers; and anionically polymerizing the two or more monomers to form a polymer having a weight average molecular weight and/or a number average molecular weight of about 2000 daitons or more {preferably about 3000 daitons or more), the polymer including the first monomer and the second monomer. The second monomer may be a 1 ,1- disubstituted alkene compound or a different monomer capable of copoiymerizing with the first monomer. Preferably the polymer is a random copolymer. The concentration of the solvent typically is about 25 weight percent or more, based on the total weight of the solvent and the two or more monomers.

[15] Another aspect of the disclosure is directed at a process comprising the steps of: mixing at least a first monomer and a solvent to form a solution including the first monomer and the solvent: wherein the first monomer is a ftrst 1 ,1 -disubstituted alkene compound: adding an initiator; anionically polymerizing the first monomer in the presence of the solvent to form a first polymer block including the first 1 , 1 -disubstituted alkene compound and having a weight average molecular weight or a number average molecular weight of about 1000 daitons or more, wherein the first polymer block has a reactive end; after polymerizing the first polymer block, adding at least a second monomer to the solvent to form a solution including the second monomer and the solvent, wherein the second monomer is different from the first monomer {e.g., the second monomer is a second 1 , 1 -disubstituted alkene compound different from the first 1 ,1-disibustituted alkene compound; reacting the second monomer to the reactive end of the first polymer block; and anionically polymerizing the second monomer to form a second polymer block. The second polymer block includes the second monomer and preferably has a weight average molecular weight or number average molecular weight of about 1000 daitons or more. The second polymer block may have a reactive end. The second polymer block has a composition different from the composition of the first polymer block. The concentration of the solvent typically is about 25 weight percent or more, based on the total weight of the solvent and the two or more monomers. The block copolymer may be a dib!ock copolymer or may have one or more additional po!ymer blocks {e.g.. 3 or more blocks). The first polymer block and/or the second polymer block may include one or more additional monomers {e.g., different from the first 1 ,1-disubstituted alkene compound, and different from the second monomer).

[18] Another aspect of the disclosure is directed at a process comprising the steps of: mixing one or more monomers {including a first monomer that is a 1 ,1-disubsiituted alkene compound) and a solvent; adding an activator; reacting the activator with one of the one or more monomers (e.g., with the first monomer) for initiating the anionic polymerization of the one or more monomers; and anionica!iy polymerizing the one or more monomers to form a polymer having a weight average molecular weight and/or a number average molecular weight of about 2000 daitons or more, the polymer including the first monomer, wherein the first monomer is provided as a high purity monomer having a purity of about 95 weight percent or more. Preferably the high purity monomer has a purity of about 97 weight percent, even more preferably about 99 weight percent. For example, the high purity monomer may include the 1 ,1-disubstituted a!kene compound having an alkene group and the total concentration of any analogous compound (i.e., impurity compound) having the alkene group replaced by hydroxyaiky! group is about 3 mole percent or less (preferably about 1 mole percent or less, even more preferably about 0.1 mole percent or less, and most preferably about 0.01 moie percent or less), based on the total moles of the 1 ,1-dtsubstituted alkene compound. The concentration of the solvent typically is about 25 weight percent or more, based on the total weight of the soivent and the two or more monomers.

[17] Another aspect of the disclosure is directed at a polymer including one or more 1 ,1- disubstituted alkene monomers. The polymer may be prepared using a solution polymerization reaction, such as a reaction according to the teachings herein.

[18] Another aspect of the disclosure is directed at a polymeric composition comprising (1 ) a polymer including one or more 1 , 1-disubstituted alkene monomers and (2) one or more additives,

[19] Another aspect of the disclosure is directed at a system for polymerizing one or more monomers including a reactor having an agitation device for mixing a monomer and a solvent; about 25 weight percent or more soivent; and about 2 weight percent or more of one or more monomers including one or more 1 ,1-disubstituted a!kenes. Preferably the agitation device includes a stirring device. The system preferabl includes an activators) for initiating anionic polymerization of 1 , 1-disubstituted alkenes.

[20] Another aspect of the disclosure is directed at a block copolymer having a first polymer block including a first primary monomer that is a 1 ,1 -disubstituted alkene compound, wherein the first primary monomer is present at a concentration of about 50 weight percent or more, based on the total weight of the first polymer block, the first polymer block cova!enfSy bonded to a second polymer block including a second primary monomer different frotTt the first primary monomer, wherein the second primary monomer is present at a concentration of about 50 weight percent or more, based on the iota! weight of the second polymer block.

[21] Another aspect of the disclosure is directed ai a low molecular weight polymer having a number average degree of polymerization from about 4 to about 50 and/or a number average molecular weight from about 800 daitons to about 10000 dalions {e.g., from about 800 to about 8S0Q dattons).The iow molecular weight polymer includes about 60 weight percent or more of one or more 1 , 1 -^substituted aikene compounds, based on the total weight of the iow molecular weight polymer. Preferably the low molecular weight polymer includes a primary monomer present at about 90 weight percent or more, based on the total weight of the low molecular weight polymer, and the primary monomer is one of the one or more t ,1-disubstituted aikene compounds. The low molecular weight polymer preferably has a polydispersity index of about 5 or less.

[22] The methods according to the teachings herein may be employed to produce a polymer including one or more 1, 1-disubstituted aikene monomers having improved control of molecular weight, improved control of molecu!ar weight distribution, or both. For example, a solution polymerization method (such as one according to the teachings herein) may be employed for controliabiy producing iow molecular weight polymers including a 1 ,1- disubstituted aikene monomer. The methods according to the teachings herein may be employed to controliabiy produce high molecular weight polymers including a 1 ,1- disubstituted aikene compound. The methods according to the teachings herein may be employed to produce a random copolymer including two or more 1 ,1-disubsfitufed aikene monomers having improved control of the monomer sequence distribution. The methods according to the teachings herein may be employed to produce a block copolymer including two different polymer blocks, the block copolymer including one or more 1 ,1-disubstituted aikene monomers. The methods according to the teachings herein may be employed to produce a solution having generally high polymer concentration (e.g., about 2 weight percent or more, or about 5 weight percent or more) and/or having low viscosity. The methods according to the teachings herein may be employed to produce polymers using anionic polymerization with a throughput rate of about 10 kg/hour o more and/or in a reactor system having a volume {e.g., of the solution) of about 20 liter or more. For example, the methods according to the teachings herein may better control the temperature during the polymerization, even when using pilot scale or manufacturing scale production {e.g., so that the process is generally free of temperature spikes during polymerization).

BRIEF DESCRIPTION OF THE DRAWINGS [23] FIG. 1 is a drawing illustrating features of a system for solution polymerization of a polymer including a 1 ,1-disubstituted a!kene monomer according to the teachings herein using anionic polymerization.

[24] RG. 2 is a diagram illustrating features of a process for polymerization of a polymer including a 1 ,1-disubstituted alkene monomer using anionic polymerization.

[25] FiGs, 3A and 3B depict representative NfVSR spectrograms illustrating the conversion of monomer to polymer via solution polymerization. FIG. 3A is taken at an early stage of the polymerization reaction and the peak at 6.45 ppm identifies the presence of unreacted monomer. FIG. 36 is taken at a later stage of the polymerization reaction and there is no detectable peak at 6.45 ppm.

[26] F!G, 4A, 48, and 4C are differential scanning caloriroetry (DSC) curves of polymers prepared by anionic polymerization in solution according to the teachings herein, measured at a heating rate of about 10 /rnin using a sample size of about 7 mg showing the giass transition temperature of the po!ymer. FIG.4A is a DSC curve of a homopoiymer of 2~phenyl~ 1 -propanoi ethyi methylene malonate. FIG. 4B is a DSC curve of a homopoiymer of fenchyl methyl methyiene malonate. FIG. 4C is a DSC curve of a random copolymer of 2-phenyl-1- propanoS ethyl methyiene malonate (about 50 weight percent) and fenchyS methyS methylene malonate (about 50 weight percent).

[27] F!Gs. 5A, 58, 5C, and 5D are representative GPC chromatograms of polymers according to the teachings herein. The GPC chromatograms may be employed for the characteri ation of the molecular weight distribution.

DETAILED DESCRIPTION

[28] Surprisingly, it has been found that a monomer including a 1 ,1-disubstituted a!kene may be anionicaily polymerized using a solution polymerization process to control!abiy produce polymers (e.g., to produce polymers having controlled molecular weight and/or structure), in the solution polymerization process, the monomers are diluted by a solvent and the monomer and solvent form a single continuous phase. During the polymerization process the resulting polymer may be soluble in the solvent, or may precipitate from the solvent. Preferably, the polymer is soluble in the solvent during some or ail of the polymerization process. For example, the solvent and/or the reaction conditions (such as the solvent concentration, the polymerization temperature) may he selected so that the polymer is soluble in the solvent during some or all of the polymerization process. The methods according to the teachings herein may be used to prepare a homopoiymer or a copolymer. For example, the polymer may be a random copolymer or a block copolymer.

[29] FIG. 1 illustrates features that may be employed in a solution polymerization system according to the teachings herein. The solution polymerization system 10 includes a continuous liquid phase 13 and optionally a dispersed polymer precipitate phase 20 (not shown). St wili be appreciated that prior to a polymerization reaction, the liquid phase may include solvent 12, monomer 14 and be substantially free of any polymer 26. The polymerization may start {i.e., initiate} with the addition of activator 16. it will be appreciated that the activator 16 may be reapidly consumed during the irritation reaction. After a polymerization reaction begins, the polymer 26 may initially be in the liquid phase 18. As the polymer molecules grow, some or ail of the poiymer 26 may opiionaiiy precipitate out of the liquid phase 18 into a dispersed phase 20 {not shown), if a dispersed poiymer phase 20 is formed, the dispersed phase may include the poiymer 26 and opiionaiiy a portion of the monomer 14 and/or a portion of the soivent 12. The monomer 14 may be completely converted so that eventually the polymerization system 10 includes poiymer 26 and is substantially or entirely free of monomer 14, The continuous liquid phase 18 may include or consist substantially (e.g., about 90 volume percent or more or about 98 volume percent or more based on the total volume of the continuous liquid phase) of the solvent 12, the monomer 14, and the poiymer 26. The monomer 14 and/or poiymer 28 preferably includes one or more 1 ,1-disubstituted aikene compounds (e.g., one or more 1 ,1-disubstituted ethylene compounds).

[30] The monomer typically includes one or more 1 ,1-disubstituted aikene compounds (e.g., one or more 1 ,1-disubstituted ethylene compounds). The 1 ,1 -disubstituted aikene preferably is a primary monomer (i.e., a monomer present at 50 weight percent or more of a polymer block or of an entire polymer). 1 , 1-disubstituted aikene compounds are compounds (e.g., monomers) wherein a centra! carbon atom is doubly bonded to another carbon atom to form an ethylene group. The centra! carbon atom is further bonded to two carbony! groups. Each carbony! group is bonded to a hydrocarbyl group through a direct bond or an oxygen atom. Where the hydrocarbyl group is bonded to the carbony! group through a direct bond, a keto group is formed. Where the hydrocarbyl group is bonded to the carbony! group through an oxygen atom, an ester group is formed. The 1 ,1-disubstituted aikene preferably has a structure as shown below in Formula i, where X^! and X" are an oxygen atom or a direct bond, and where R¹ and are each hydrocarbyl groups that may be the same or different. Both X¹ and may be oxygen atoms, such as illustrated in Formuia HA, one of X¹ and X² may be an oxygen atom and the other may be a direct bond, such as shown in Formula i!B, or both X¹ and X² may be direct bonds, such as illustrated in Formula l!C, The 1 ,1- disubstituted aikene compounds used herein may have ali ester groups (such as illustrated in Formula HA), all keto groups (such as illustrated in Formula I IB) or a mixture thereof {such as illustrated in Formula IIC). Compounds with all ester groups are preferred due to the flexibility of synthesizing

Formu!a I

Formula lie

[31] One or more as used herein means that at least one, or more than one, of the recited components may be used as disclosed. Nomina! as used with respect to functionality means the theoretica! functionaiity, generaiiy this can be calculated from the stoichiometry of the ingredients used. Generaiiy, the actual functionaiity is different due to imperfections in raw materials, incomplete conversion of the reactants and formation of by-products. Durability in this context means that the composition once cured remains sufficiently strong to perform its designed function, in the embodiment wherein the cured composition is an adhesive, the adhesive holds substrates together for the life or most of the life of the structure containing the cured composition. As an indicator of this durability, the curable composition (e.g., adhesive) preferably exhibits excellent results during accelerated aging. Residual content of a component refers to the amount of the component present in free form or reacted with another materia!, such as a polymer. Typically, the residual content of a component can be calculated from the ingredients utilized to prepare the component or composition. Alternatively, ft can be determined utilizing known analytical techniques. Heteroaiom means nitrogen, oxygen, sulfur and phosphorus, more preferred heteroatoms include nitrogen and oxygen. Hydrocarbyl as used herein refers to a group containing one or more carbon atom backbones and hydrogen atoms, which may optionally contain one or more heteroaioms. Where the hydrocarbyl group contains heteroatoms, the heteroatoms may form one or more functional groups we!! known to one skilled in the art. Hydrocarbyl groups may contain cycloaliphatic, aliphatic, aromatic or any combination of such segments. The aliphatic segments can be straight or branched. The aliphatic and cycloaliphatic segments may include one or more doub!e and/or triple bonds. Included in hydrocarbyl groups are a!kyl, aikenyl, alkynyl, aryl, cycfoafkyl, cycloaikenyi, aikary! and ara!kyl groups. Cycloaliphatic groups may contain both cyclic portions and noncyciic portions. H drocarbyiene means a hydrocarbyl group or any of the described subsets having more than one valence, such as aikylene, alkeny!ene, aikyny!ene, aryiene, cycioaikylene, cycloalkeny!ene, a!karyiene and aralky!ene. One or both hydrocarbyl groups may consist of one or more carbon atoms and one or more hydrogen atoms. As used herein percent by weight or parts by weight refer to, or are based on, the weight of the solution composition unless otherwise specified.

[32] Unless defined otherwise, al! technical and scientific terms used herein have the meaning commonly understood by a person skilled in the art to which this disciosure belongs. The following references provide one of skill with a general definition of many of the terms used in this disciosure: Singleton et a ., Dictionary of Microbiology and Molecular Biology (2nd ed. 1994); The Cambridge Dictionary of Science and Technology (Walker ed„ 1988); The Glossary of Genetics, 5th Ed._s R. Rieger et al. {eds.}, Springer Verlag (1991 ); and Hafe & Marham, The Harper Collins Dictionary of Biology (1991 ). As used herein, the following terms have the meanings ascribed to them below, unless specified otherwise.

[33] 1 ,1-disubstituted aikene compound means a compound having a carbon with a double bond attached thereto and which is further bonded to two carbon atoms of carbonyl groups. A preferred class of 1 ,1-disubstituted a!kene compounds are the methylene malonafes which refer to compounds having th core formula

The term "monofunctiona refers to 1,1~ fsubsfi†uted aikene compounds or a methylene malonates having only one core formula. The term "difunctiona!" refers to 1 ,1-disubstituted aikene compounds or a methylene malonates having two core formulas bound through a hydrocarbyl linkage between one oxygen atom on each of two core formulas. The term ''multifunctional'' refers to 1,1~disubstituted aikene compounds or methylene malonates having more than on core formula which forms a chain through a hydrocarbyl linkage between one oxygen atom on each of two adjacent core formulas. The term latent acid- forming impurities" or 'latent acid-forming impurity" refers to any impurity that, if present along with the 1 ,l-disub8tituted aikene compounds or methylene malonates, will with time be converted to an acid. The acid formed from these impurities may result in overstabilizaiion of the 1 ,1-disufastifuted aikene compounds, thereby reducing the overa!! quality and reactivity of the compounds. The term "ketai" refers to a moSeeuie having a ketal functiona!ity; i.e., a molecule containing a carbon bonded to two -OR groups, where O is oxygen and R represents any a!kyj group. The terms "volatile" and "non-volatile" refers to a compound which is capable of evaporating readily at normal temperatures and pressures, in the case of volatile; or which is not capable of evaporating readi!y at normal temperatures and pressures, in the case of non-volatile. As used herein, the term "stabilized" (e.g., in the context of "stabilized" 1 ,1-disubstituted aikene compounds or monomer compositions comprising same) refers to the tendency of the compounds (or the monomer compositions), prior to activation with an activator, to substantially not polymerize with time, to substantially not harden, form a ge!, thicken, or otherwise increase in viscosity with time, and/or to substantially show minima! loss in cure speed (i.e., cure speed is maintained) with time. As used herein, the term "shelf-life" {e.g., as in the context of 1,1-disubstituted aikene compounds having an improved "she!f-life") refers to the 1 ,1-disubstituted aikene compounds which are stabilized for a given period of time; e.g., 1 month, 6 months, or even 1 year or more.

[34] The hydrocarbyl groups (e.g., R¹ and R²}, each comprise straight o branched chain alkyi, straight or branched chain a!kyi a!kenyi, straight or branched chain alkyny!, cyc!oaikyl, alky! substituted cycioaiky!, aryi, araikyi, or aikaryi. The hydrocarbyl group may optionally include one or more heteroatoms in the backbone of the hydrocarbyl group. The hydrocarbyl group may be substituted with a substiiuent that does not negatively impact the ultimate function of the monomer or the polymer prepared from the monomer. Preferred substiiuenfs include alkyi, halo, a!koxy, aiky!thio, hydroxy!, nitro, cyano, azido, carboxy, acyloxy, and suifonyi groups. More preferred subs!ituents include alkyi, halo, a!koxy, alyiihio, and hydroxy! groups. Most preferred substituents include halo, a!ky!, and alkoxy groups. [35] As used herein, a!kary! means an alkyi group with an ary! group bonded thereto. As used herein, aralky! means an aryl group with an a!kyi group oonded {hereto and inciude aikyiene bridged aryi groups such as diphenyl methyi groups or diphenyl propyl groups. As used herein, an ary! group may inciude one or more aromatic rings. CycSoaiky! groups inciude groups containing one or more rings, optionally including bridged rings. As used herein, alkyi substituted cycioaikyl means a cycioaikyl group having one or more aikyi groups bonded to the cycioalky! ring.

[36] Preferred hydrocarbyi groups inciude 1 to 30 carbon atoms, more preferably 1 to 20 carbon atoms, and most preferably 1 to 12 carbon atoms. Preferred hydrocarbyi groups with heteroatonis in the backbone are a!kyl ethers having one or more alkyi ether groups or one or more aikyiene oxy groups. Preferred alky! ether groups are ethoxy, propoxy, and butoxy. Preferably such compounds contain from about 1 to about 100 aikyiene oxy groups and mote preferably about 1 to about 40 aikyiene oxy groups and more preferably from about 1 io about 12 aikyiene oxy groups, and most preferably from about 1 io about 6 aikyiene oxy groups.

[37] One or more of the hydrocarbyi groups (e.g., ¹, R², o both), preferably includes a CM₅ straight or branched chain alkyi, a Ο _Ιί. straight or branched chain a!kenyi, a C₅.₁₈ cycioaikyl, a 0_δ._ϊ4 alkyi substituted cycioaikyl, a C .18 a yi, a C4.20 aralkyl, or a C4.2.3 aralkyl. More preferably, the hydrocarbyi group, includes a C_; « straight or branched chain alkyi, a C_:., ₁₂ cycioaikyl, a ¾.« aikyi substituted cycioaikyl, a C₄.₁₈ aryl, a C^o aralkyl, or a 0 ._2δ aralkyl.

[38] Preferred alkyi groups include methyi, propyl, isopropyl, butyl, tertiary butyl, hexyl, ethyl pentyl, and hexyl groups. More preferred aikyi groups include methyi and ethyl. Preferred cyclaikyi groups inciude eyc!ohexy! and fenchyi. Preferred alky! substituted groups inciude mentbyS and isobornyi.

[39] Most preferred hydrocarbyi groups attached to the carbonyi group inciude methyi, ethyl, propyl, isopropyl, butyl, tertiary., pentyi, hexyl, octy!, fenchyi, menthyl, and isobornyi, [40] Particularly preferred monomers include methyi propyl methylene maionate, dihexyi methylene malonate, di-isopropyi methylene malonate, butyi methyi methylene malonate, ethoxyethyi ethyl methylene malonate, methoxyethy! methyi methylene malonate, hexyl methyl methylene maionate, dipeniyi methylene maionate, ethyi pentyl methylene malonate, methyi pentyi methylene malonate, ethyl ethy!methoxy methylene malonate, ethoxyethyi methyl methylene maionate, butyi ethyl methylene malonate, dibutyi methylene malonate, diethyl methylene maionate (OE M), diethoxy ethyl methylene malonate, dimethyl methylene maionate, di-N-propy! methylene maionate, ethyi hexyl methylene malonate, methyi fenchyi methylene malonate, ethyl fenchy! methylene malonate, 2 pheny!propyl ethyi methylene maionate, 3 phenylpropyi ethyl methylene maionate, and dimethoxy ethyi methylene maionate. [41] Some or a!! of the 1 , -disubslituted alkenes can aiso be multifunctional having more than one core unit and thus more than one aikene group. Exemplary multifunctional 1 ,1-

wherein R¹, R² and X are as previousiy defined; n Is an integer of 1 or greater; and R is a hydrocarbyi group, and the 1 ,1-disubstituted aikene has n + 1 alkenes. Preferably n is 1 to about ?, and more preferably 1 to about 3, and even more preferably 1. in exemplary embodiments R^:: is, separately in eac occurrence, straight or branched chain aiky!, straight or branched chain alkenyl, straight or branched chain alkynyl, eyciaaikyi, alky! substituted cycloa!ky!, aryi, aralkyi, or aikaryi, wherein the hydrocarbyi groups may contain one or more heteroatoms in the backbone of the hydrocarbyi group and may be substituted with a substituent that does not negatively impact the ultimate function of the compounds or polymers prepared from the compounds. Exemplary substituents are those disclosed as useful with respect to R¹. in certain embodiments R^l is, separately in each occurrence, C straight or branched chain alky!, C _a,₁₅ straight or branched chain aSkenyl, C ^ eyciaaikyi, C aikyl substituted cycloalky!, C ψ₁₈ aryi, C ₄.₂o aralkyi or C 4.20 aralkyi groups, in certain embodiments R² is separately in each occurrence C _s._s straight or branched chain alky!, C _r>- ₁2 cycioaikyl, C _g. ;₂ alky! substituted cycioaikyl, C ₄.<₈ aryl, C 4. ¾> aralkyi or C 4.20 aikaryi groups.

[42] it will be appreciated according to the teaching herein, the one or more monomer may include a comonomer that is a 1 ,1-disubstituted aikene compound having a hydrocarbyi group bonded to each of the carbonyi groups through a direct bond (e.g., a carbon-carbon bond) or an oxygen atom, such as a monomer having one or more features described above, if included, a comonomer may optionally be a monomer that is not a 1,1-disubstituted aikene compound. Any comonomer capable of anionic polymerization may be employed. For example, the comonomer may be capable of forming a random copolymer with a 1 ,1- disubstituted aikene compound, capable of forming a block copolymer with a 1 ,1- disubstituted aikene compound, or both.

[43] The 1 ,1-disubstituted aikene compound preferably is prepared using a method which results in a sufficiently high purif so that it can be poiymerized. The purity of the 1 ,1- disubstituted aikene compound may be sufficiently high so that 70 mole percent or more, preferab!y 80 mole percent or more, more preferably 90 mole percent or more, even more preferabiy 95 moie percent or more, and most preferabiy 99 mole percent or more of the 1 ,1- disubstituted alkene compound is converted to poiymer during a polymerization process. The purity of the 1 ,1-disubstituted alkene compound preferabiy is about 85 moie percent or more, more preferably about 90 mole percent or more, even more preferably about S3 moie percent or more, even more preferably about 95 mole percent or more, even more preferably about 97 moie percent or more, and most preferabiy about 99 mole percent or more, based on the total weight of the 1 ,1-disubstituted alkene compound. If the 1 ,1-disubstitute alkene compound includes impurities, preferabiy about 40 moie percent or more, more preferabiy about SO moie percent or more of the impurity molecules are trie analogous 1 ,1-disubstiied aikane compound. The concentration of any impurities having a dioxane group preferably is about 2 moie percent or less, more preferabiy about 1 mole percent or less, even more preferably about 0.2 mole percent or less, and most preferably about 0.05 moie percent or less, based on the total weight of the 1 ,1-disubstituted alkene compound. The total concentratio of any impurity having the alkene group replaced by an analogous hydroxy alky! group {e.g., by a Michael addition of the alkene with wafer), preferabiy is about 3 moie percent or less, more preferabi about 1 moie percent or iess, even more preferably about 0.1 moie percent or iess, and most preferably about 0.01 moie percent or less, based on the total moles in the 1 ,1-disubstituted alkene compound. Preferred 1 ,1-disubstituted alkene compounds are prepared by a process including one or more (e.g., two or more) steps of distilling a reaction product or an intermediate reaction product (e.g., a reaction product or intermediate reaction product of a source of formaldehyde and a maionic acid ester).

[44] The 1 ,1-disubstituted aikene compound may include a monomer produced according to the teachings of U.S. Patent 8,609,885 { aiofsky et ai.) incorporated herein by reference in its entirety. Other examples of monomers which may be employed include the monomers taught in international Patent Application Publication Nos, WO2013/066629 and WO 2013/059473, both incorporated herein by reference.

[45] The concentration of the monomer in the solution polymerization process may be sufficiently low so that after polymerization, the so!ution can f!ow. if the concentration of the monomer is too high, the solution becomes too viscous at the end of the polymerization process and the solution may be difficult to handle. The concentration of the monomer in the solution polymerization process may be suffieientiy high so that the polymerization process is economical. The one or more monomers is preferably present at a concentration of about 0.5 weight percent or more, more preferably about 2 weight percent or more, even more preferabiy about 5 weight percent or more, and most preferably about 8 weight percent or more, based on the total weight of the solvent and monomer. The one or more monomers may be present at a concentration of about 90 weight percent or less, preferably about 75 weight percent or less, more preferably about 50 weight percent or less, even more preferably about 30 weight percent or less, and most preferably about 20 weight percent or less, if the monomer is added at multiple times (such as continuous and/or sequential monomer addition), it will be appreciated that the amount of the one or more monomers refers to the total amount of monomer and pofymer and by-products of the monomer that are present when the addition of monomer has been completed.

[46] SOLVENT

[47] The polymerization process includes one or more solvents selected so that the monomer and solvent form a singie phase. Preferably the solvent does not chemically react with the other components of the solution polymerization system during the poiymenzation process. For example, the solvent preferably does not react with the monomer. As another example, the soivent preferably does not react with the activator. As such, the amount of the solvent present at the end of the polymerization reaction may be substantially the same as the amount of solvent present at the start of the polymerization reaction. For example the change in the amount of solvent may be about 20% or less, preferably about 10% or less, more preferably about 5 % o less, even more preferably about 1 % or less, and most preferably about 0.2 % or less, based on the initial weight of the solvent at the start of the polymerization process.

[48j Preferred solvents are organic solvents, or mixtures of organic solvents. Such solvents, or solvent mixtures typically are in a liquid state at the reaction temperature(s) (e.g., during activation and/or during polymerization.

[493 Trie pressure of the soivent (e.g., organic soivent) and of the monomer at the polymerization temperature should be sufficiently low so that the risk of the reactor failing from over-pressure is reduced or eliminated. For example the partial pressure of the solvent, of the monomer, or both, at the polymerization temperature may be about 500 Torr or less, about 200 Torr or less, about 50 Tore or less, or about 5 Torr or less.

[SO] The solven may include one or more protic solvents, one or more aprotic solvents, or both. Preferably the soivent includes, consists essentially of, or consists entirely of one or more aprotic solvent. An aprotic solvent may include one or more polar aprotic solvent and/or one or more nonpolar aprotic solvents. Preferred aprotic solvents include, consist essentially of, or consist entirely of one or more polar aprotic solvents. Most preferably, the soivent is substantially free of {e.g., having a concentration of less than about 10 weight percent, less than about 5 weight percent, or iess than 1 weight percent of the solvent) protic solvents and/or nonpolar aprotic solvents. Examples of solvents which may be employed include alkanes, aryl containing compounds, alcohols, acetates, hydrofurans, ketones, ha!ocarbon containing compounds, and mixtures thereof. More preferred solvents include acetates, hydrofurans, ketones, ha!ocarbon containing compounds, and mixtures thereof. Preferred solvents are compounds having a mo!ecular weight of about 200 g/moSe or less, more preferably about 120 g/moie or less, and most preferably about 80 g/mole or less. Particularly preferred solvents include ietrahydrofuran, n-propy! acetate, benzene, and xylene.

it may be desirable for the soivent to be substantially or entirely free of any solvent that may react with the monomer via Michael addition. However, by selecting reaction conditions so that the polymerization reaction is sufficiently fast, it may be possible to employ such monomers in the solvent polymerization process. For example, by selecting parameters such as monomer feed rates, reaction temperature, monomer type, and H, it may be possible to employ a solvent including or consisting of a protie solvent, such as an alcohol.

[52j The soivent may be selected to be generally compatible or miscib!e with one or more of the monomers (e.g., with the primary monomer), with the poiymer {e.g. , with one or more blocks of a b!ock copolymer}, or both. For example, the soivent and the monomer may be characterized by Hildebrand solubility parameters that differ by about 5 (MPa) ^:' or less, more preferabiy that differ by about 2 <MPa) ⁱ² or less, even more preferably that differ by about 1 (MPa)^{1 2} or less, even more preferably that differ by about 0.7 {yPa)^1,¾ or less, and most preferably that differ by about 0.4 {UPa) or less. The soivent and monomer may have about the same Hildebrand solubility parameter. In some aspects, it may be desirable for the polymer to remain in solution until after polymerization is complete, in other aspects, it may be desirable for the poiymer to precipitate out {e.g., by forming a phase that is rich in the poiymer, that consists essentially of the polymer, or that consists entirely of the polymer) during the polymerization process,

[53] if the concentration of solvent is too low, the solution becomes too viscous at the end of the polymerization process and the solution may be difficult to handle. The solvent may be present af a concentration of about 10 weight percent or more, preferably about 25 weight percent or more, more preferably about 35 weight percent or more, even more preferably about 45 weight percent or more, even most preferabiy about 50 weight percent or more, based on the total weight of the soivent and monomer, in cases where increased control is critical, the concentration of the solvent may be about 60 weight percent or more, or about 85 weight percent or more, based on the total weight of th solvent and monomer. The soivent is preferably present at a concentration of about 99.5 weight percent or less, more preferabiy about 98 weight percent or less, even more preferabiy about 95 weight percent or less, and most preferably about 92 weight percent or less, based on the total weight of the soivent and monomer.

[54] It may be desirable for the polymer to be isolated from some or all of the solvent. As such, it may be advantageous to select a solvent that forms a single phase with the monomer, but after polymerizing the monomer to a desired molecular weight (e.g., number average molecular weight) the polymer wi!i precipitate out of solution. Alternatively, after the completion of polymerization, a compound that is a poor solvent to the poiymer may be added to the solution to cause the poiymer to precipitate out, such as described herein.

[55] The solution polymerization ma be initiated using an activator capable of initiating anionic polymerization of the 1 , 1-disubstituted alkene containing compound. The activator may be a compound that is a nucleop i!e or a compound that forms a nuc!eophtle. Examples of activators (i.e., initiators}, which may be employed, include ionic metai amides, hydroxides, cyanides, phosphines, aSkoxides, amines and organometallic compounds (such as a!kyiiithium compounds ), and metal benzoates. The polymerization activator may have one or more of the features (e.g., include one or any combinations of the activating agents and/or polymerization activators, include an activating agent at a concentration or concentration range, or include a process step) as described in US patent Application publication US 2015/0073110 A1 published on Ma ch 12, 2015, incorporated herein by reference (e.g., see paragraphs 0024 to 0050). By way of example, the activator may include, consist essentially of, or consist entireiy of one or more metal benzoates, such as sodium benzoate. The molecular weight of the polymer may be adjusted by adjusting the molar ratio of the monomer to the activator. Preferably the molar ratio of the monome to activator is about 5 or more, about 50 or more, about 100 or more, about 500 or more, or about 1 ,000 or more. The mo!ar ratio of the monomer to the activator preferably is about 100,000 or less, about 50,000 or less, about 10,000 or less, or about 2,000 or less, A particularly preferred activator for the anionic polymerization: process according to the teachings herein is sec-butyl lithium. Sec-buyi lithium may be employed in activating the polymerization of a homopo!ymer or of a copolymer (e.g., a random copolymer, or a block copolymer).

[58j According to certain embodiments, a suitable polymerization activator can generally be selected from any agent that can initiate polymerization substantially upon contact with a selected polymerizabie composition, in certain embodiments, it can be advantageous to select polymerization initiators that can induce polymerization unde ambient conditions and without requiring externa! energy from heat or radiation. In embodiments wherein the polymerizabie composition comprises one or more 1 , 1-disubstituted alkene compounds, a wide variety of polymerization initiators can be suitable including most nucieophs!ic initiators capable of initiating anionic polymerization. For example, suitable initiators include alkali metal salts, alkaline earth metal salts, ammonium salts, amine salts, ha!ides (halogen containing salts), metai oxides, and mixtures containing such salts or oxides. Exemplary anions for such salts include anions based on halogens, acetates, benzoates, sulfur, carbonates, silicates and the like. The mixtures containing such salts can be naturally occurring or synthetic. Specific examples of suitable polymerization initiators for 1 ,1- disuhsfitufed alkene compounds can include ionic compounds suc as sodium benzoate, sodium pyruvate, and tetramethy! guanidine. Additional suitable polymerization initiators for such poSynierizabie compositions are aiso disclosed in U.S. Patent Application Publication No, 2015/00731 10, whic is hereby incorporated by reference.

[57] The soiveni and/or one or more of the monomers {e.g., the 1 ,1-disubstituted aikene compounds) may further contain other components to stabilize the monomer prior to exposure to polymerization conditions or to adjust the properties of the finai polymer for the desired use.

Prior to the polymerization reaction, one or more inhibitors may be added to reduce or prevent reaction of the monomer. Such inhibitors may be effective in preventing anionic polymerization of the monomer, free radical polymerization of the monomer, reaction between the monomer and other molecules (such as water), or any combination thereof.

[58] An acid containing compound may be employed in the solution polymerization process. With various monomers, the use of an acid containing compound may be employed to reduce the reaction rate, decrease the pol dispersity, or both. When the concentration of the acid containing compound is too high, the polymerization reaction may be too slow for commercial viability. When the concentration of the acid containing compound is too low, the polymerization reaction may result in a polymer having rapid and/or uncontrolled buildup of molecular weight. The acid containing compound may be an organic compound having one or more acid groups. For example, the acid containing compound may include one or more acid groups having a sulfur, phosphorous, chlorine, or bromine, fluorine or nitrogen atom. The acid containing compound preferably includes one or more nitrogen atoms (such as in a nitrate or nitrite group) and/or one or more sulfur atoms (such as an aikyl or aryi sulfonic acid. Particularly preferred acid containing compounds include methanesulfonic acid and benzoic acid, it will be appreciated that the acid containing compounds may affect the initiation, propagation, or termination of the polymer. The weight ratio of the acid containing compound to the amount of the monomer employed for a polymerization step (e.g., for polymerizing a first poiymer block) preferably is about 0.00005 or more, more preferably about 0.0002 or more and most preferably about 0.0005 or more. The weight ratio of the acid containing compound to the amount of the monomer employed for a polymerization step (e.g., for polymerizing a first poiymer block) preferably is about 0.2 or less, more preferably about 0.04 or less, and most preferably about 0.005 or less.

[59] The polymerization process may include a step of applying shear forces to a mixture including at least the monomer and the solvent. For example, the process may include stirring or otherwise agitating the mixture for creating the solution, for dispersing or removing a precipitated polymer, for controlling thermal gradients, or any combination thereof. [60] The polymerization process may be a batch process {e.g. , using a single batch reactor or a series of batch reactors). The polymerization process may be in a continuous process, such as a process that transports a solution along the length of a reactor, in a batch process, or in a continuous process, all of the monomer may be added at a single stage (e.g., prior to the addition of the polymerization activator, or at or near the start of the polymerization reaction) or may be added at multiple stages in the polymerization reaction.

[61] The polymerization process may be employed for polymerization of a homopoiymer or a copolymer, such as a random copolymer or a block copolymer. The homopoiymer or copolymer includes one or more 1 ,1-disubstituted a!kene containing compounds according to the teachings herein. Preferably, the amount of the 1,1-disubstituted aikene containing compounds in the polymer is about 5 weight percent or more, more preferab!y about 30 weight percent or more, even more preferably about 50 weight percent or more, even more preferably about 70 weight percent or more, based on the total weight of the polymer. For example, one or more of the polymer blocks may consist essentially of, or entirely of the 1 ,1- disubstituted aikene containing compounds.

[62j A mufti-stage addition of monomer may be employed for polymerization of a block copolymer having polymer blocks with different compositions. For example, a block copolymer ma have a first polymer block, (block A), and a second polymer block (block 8). The block copolymer may have 2 or more blocks or 3 or more blocks. The A block and 8 block may include at least one monomer that is the same (however at different concentrations), or may include only monomers that are different. For example, the A block may be a homopoiymer of a first monomer, and the B block may include one or more second monomers which are each different from the first monomer. The first polymer block may be a homopoiymer or a copolymer (e.g., a random copolymer). The second polymer block may be a homopoiymer or a copolymer {e.g., a random copolymer). The first polymer block and the second polymer block preferably each inciude one or more 1 ,1-disubstituted aikene containing compounds according to the teachings herein. Preferably, the amount of the 1 ,1- disubstituted aikene containing compounds in the first polymer block and/or in the second polymer block may be about 30 weight percent or more, preferably about 50 weight percent or more, even more preferably about 70 weight percent or more, based on the total weight of the polymer block. For example, one or more of the polymer blocks may consist essentially of, or entirely of the 1 ,1-disubstituted aikene containing compounds, it will be appreciated that one or more blocks may be substantially or entirely free of any 1 ,1-disubstituted aikene containing compounds. For example, one or more of the polymer blocks may include one or more conjugated diene monomers and/or one or more styrenic monomers.

[63] During the polymerization process, the solution is preferably stirred or otherwise agitated to create the solution. For example, the solution including the monomer, the solvent, and any polymer may be mixed at a rate of about 10 rpm or more, about 50 rpm or more, about 200 rpm or more, or about 1 ,000 rpm or more.

[64] The solution polymerization process preferably includes a reaction temperature at which the partial pressure of the solvent is generally low. For example, the partial pressure of the solvent and/or the monomer may be about 400 Torr or less, about 200 Torr or less, about 100 Torr or less, about 55 Torr or less, or about 10 Torr or less. The reaction temperature preferably is about 80 ^SC or less, more preferably about 70 ¾ or less, even more preferably about 80 *C or less, even more preferably about 55 °C or less, even more preferably about 45 ^eC or less, even more preferably about 40 "C or less, and most preferably about 30 °C or iess. The reaction temperature typically is sufficiently high that the solvent and the monomer are in a liquid state. For example, the reaction temperature may be about -100 "C or more, about -80 °C or more, about -30 "C or more, or about 10 ^*C or more,

[65] When polymerizing a 1 ,1-disubstituted alkene compound, it may be desirable io add one or more acid compounds to the solution, to the monomer, or both, so that the initial pH of the solution is about 7 or less, about 6.8 or less, about 6.6 or less, or about 6.4 or less, it is believed that such an initial acidic condition may be beneficial fo controlling or otherwise limiting the initiation of the monomer. For example, the 1 ,1-disubstituted alkene compound may be a compound that will auto-initiate under basic conditions and the use of an acid condition may prevent or minimize such auto-initiation. The acidic condition preferably is maintained throughout the polymerization process. If the pH is too low, the reaction rate may be fow or the reaction may be terminated. Preferably, the pH during the reaction is about 5 or more, more preferably about 5,5 or more, even more preferably about 5.9 or more, and most preferably about 6 or more. It will be appreciated that following the polymerization process the pH may be adjusted to increase or decrease the pH.

[66j The solution polymerization process may be stopped prior to the completion of the polymerization reaction or may be continued until the completion: of the polymerization reaction. Preferably, the reaction rate is sufficiently high and/or the reaction time is sufficiently long so thai the polymerization reaction is substantially complete. For example the conversion of the monomer to polymer may be about 30 weight percent or more, about 60 weight percent or more, about 90 weight percent or more, about 95 weight percent or more, or about 99 weight percent or more. The conversion of monomer to polymer may be about 100 weight percent or less.

[67] With reference to FIG. 2, the solution polymerization process 30 typically Includes a step of developing a generally homogenous solution. For example, the process may include step of combining a solvent, one or more monomers, and an activator, !i will be appreciated that the components of the solution may be added at one time, may be added at different times, or some components may be combined separately. The development of the homogeneous solution 32 typically requires agitation. Depending on the type and intensity of the agitation, it may he possible to control the rate at which the homogenous solution is developed. Th process typically Includes a step of initiating the polymerization reaction 34, The initiation step preferably occurs after the monomer and solvent have been homogenized, it will be appreciated that an activator may be added into the system prior to the addition of monomer, at the same time as the addition of the monomer, or after addition of a first portion of the monomer and prior to the addition of a second portion of the monomer. After activation of the monomer, the process includes a step of propagating the polymer by an anionic polymerization reaction 36. The propagating step may continue until all of the monomer is consumed, or until the propagation reaction is stopped, such as by quenching 38 or the conditions are altered so that further anionic polymerization reaction stops. The propagation step may also stop by a phase separation of the polymer from the monomer (e.g. , where the monomer has difficulty in contacting the reactive end of the polymer molecule). Prior to a step of quenching, there may be one or more additional steps of feed monomer (which may be the same or different from the initial monomer feed), and one or more additional steps of propagating the polymerization reaction. With each such propagating step, the polymer mo!ecuiar weight generally increases, unless conditions for addition chain activation are provided (for example by adding additional activator). It wiii be appreciated that the resulting polymer may he capable of further reaction with monomer and may thus be a living" polymer.

[683 The conversion of monomer to polymer may be measured using HMR spectroscopy, such as illustrated in FIG. 3A and FIG. 3B, corresponding to an early and a later stage of a propagation reaction for polymerizing a 1 ,1-disubstituted aikene monomer. Here, the monomer is diethyl methylene malonate and the concentration of the monomer can be monitored by the peak at about 6.45 ppm 40 corresponding to the reactive double bond of the monomer. Hexamethyidtsioxane is used here an interna! standard {i.e., internal reference) 42 and is seen at about 0 ppm. if wiii be appreciated that other compounds may be empioyed as an internal standard, in FIG. 3A, the NM spectrogram was measured on a first aliquot taken from a specimen initiated with sodium benzoate at a moiar ratio of monomer to initiator of about 100:1. The first aliquot was taken afte the reaction had propagated for about 30 seconds at room temperature. The first aliquot was quenched with an acid to stop the propagation reaction. FIG. 3B shows the MR spectrogram from a second aliquot taken from the same specimen after about 5 minutes of the propagation reaction. As seen in FIG. 36, the monomer is no longer detectable as evidenced by a lack of the reactive double bond peak at about 6,45 ppm 40. [69] The polymers according to the teachings herein preferably have a number average molecular weight or a weight average molecular weight that is about 700 g/moSe or more, more preferably about 2,000 g/rnoie or more, even more preferabiy about 10,000 g/moie or more, and most preferably about 20,000 g/mole or more. The moiecuiar weight of the polymer may be sufficiently low so that the polymer may be easiiy processed. The number average molecular weight or the weight average molecular weight preferabiy is about 3,000,000 g/moie or less, more preferably about 2,000,000 g/moie or iess, even more preferabiy about 1000,000 g/mole or iess, and most preferably about 800,000 g/moie or iess.

Tfts resulting polymer may be a relatively !ow mo!ecuiar weight poiymer having a number average molecular weight of about 40,000 g/mole or iess, about 30,000 g/mole or iess, or about 20,000 g/mole or iess. The resulting polymer may be a relatively high moiecuiar weight polymer having a number average moiecuiar weight of greater than 40,000 g/moie, about 60,000 g/mole or more, or about 100,000 g/rno!e or more.

[71] The resulting poiymer may be characterized by a poiydispersity index of about 1.00 or more or about 1 .05 or more. The resulting poiymer may be characterized by a poiydispersit index of about 20 or iess, preferabiy about 7 or less, more preferably about 4 or less, and most preferably about 2,3 or less. The resulting polymer may have a narrow moiecuiar weight distribution such that the poiydispersity index is about 1 .9 or less, about 1.7 or iess, about 1.5 or less, or about 1.3 or less.

[723 The degree of polymerization, as used herein, is generally the molecular (as defined herein) divided by the average moiecuiar weight of the monomer units. For example, the weight average degree of polymerization of a homopoiymer is the weight average molecular weight of the homopoiymer (e.g., in units based on the PM A standards) divided by the molecular weight of the monomer unit.

[73] Surprisingly, fay employing an acid containing compound according to the teachings herein, it may be possible to reduce the poiydispersity of a polymer (e.g. , of a polymer block) without a substantive reduction in the polymerization reaction rate. For example, the poiydispersity of the ratio of the poiymer prepared with the acid containing compound to the poiydispersity of a polymer prepared using the same method except without the use of the acid containing compound may be about 0.9 or iess, about 0.8 or iess, about 0.7 or iess, or about 0.6 or less. The ratio of the time for converting 80% of the monomer to polymer for the process including the acid containing compound to the time for converting 80% of the monomer to polymer in the identical process (except without the acid containing compound) preferabiy is about 5 or iess, more preferabiy about 3 or iess, even more preferabiy about 2 or iess, and most preferabiy about 1.5 or iess. [74] The molecular weight of the polymer may be measured using gel permeation chromatography (i.e., GPC), FIG.5A, illustrates a GPC curve for a homopo!ymer prepared by polymerizing diethyl methylene maSonate in an solution system. TMG is used as the activator for the anionic polymerization of the monomer. The mo!ar ratio of monomer to the activator is about 1000:1 , The reaction was continued until about 100 percent of the monomer was converted to polymer. The GPC curve 58 of the resulting homopoiymer is shown in FIG. 5A, This sample has a sing!e peak which defines an area SO for calculating the molecular weight characteristics of the polymer (e.g., weight average molecular weight, peak moiecuiar weight, number average moiecuiar weight, z-average molecular weight, and poiydispsersity index). The GPC curve 5δ shows the signal intensity (which correiates with concentration) as a function of the retention time in minutes. The calibration curve 54 is aiso shown in FiG. 5A. The calibration curve shows the retention time for a series of PUMA standards of known moiecuiar weight. The low limit 56 for measuring the moiecuiar weight based on these standards is about 2QQ da!tons. The sequential increase in the molecular weight of a biock copolymer after the addition of each of fou poiymer blocks is shown in FiG. 5A, 58, 5C, and 5D.

[75] The solution polymer according to the teachings herein may be characterized as an elastomer. For example, the resulting polymer may be substantially free of a melting temperature and substantially free of a glass transition temperature of about 15 °C or more.

[76] The solution poiymer according to the teaching herein may be characterized as a thermoplastic having a melting temperature and/or a glass transition temperature of about 15 "G or more, about 50^aC or more, about 80 ^C'C or more, about 100 ^aC or more, or about 120 "C or more. Polymers having a high glass transition temperature include those having hydrocarbonyi groups that provide sferic hindrance that reduce the mobility of poiymer molecules in the me!t state. The melting temperature and/or the glass transition temperature of the thermoplastic may be about 300 "C or less, about 250 "C or less, or about 150 "C o !ess.

[77] The solution polymer according to the teachings herein may be characterized as a block copolymer including at least one biock having a glass transition temperature or melting temperature of about 15 "C or more {e.g., about SO C or more, about 80 °C or more, or about 100 °C or more) and at ieast one different biock having no melting temperature above 15 ^"C and having a glass transition temperature of less than 15 °c (e.g. , about 10 °C or less, about 0 or less, or about -20 ^"C or less). In one aspect, a block copolymer may be prepared with blocks that are not miseibie so that the resulting biock copolymer has multiple phases at room temperature. As such, the biock copolymer may have a first glass transition temperature corresponding to the first poiymer block and a second glass transition temperature corresponding to the second polymer biock. it will be appreciated that the giass transition temperature of the biocks may be tailored based on the monomer or monomers used in the particular block and/or based on end effects (which includes the effect of the number of monomer units in the block). For purposes of illustration, a polymer block consisting essentially of, or consisting entirely of: (1 ) diethyl methylene maSonate homopoiymer is expected to have a glass transition temperature of about 25 X to about 45 X (preferably about 30 X), (2) fenchyl methyl methylene malonate is expected to have a glass transition temperature of about 125 X to about 200 {preferably about 150 X), {3} methyl methoxyethyS methylene malonate is expected to have a glass transition temperature of about -15 to about +10 "C (preferably about 0 X), (4) hexy! methyl methylene malonate is expected to have a glass transition temperature of about -45 X fo about 0 X (preferably about -34 X), (5) dibulyi methylene malonate is expected to have a glass transition temperature of about -55" C to about -35 (preferably about -44 X). it may be possible to prepare a block copolymer having multiple glass transition temperatures, suc as a first glass transition temperature characteristic of a first polymer block and a second giass transition temperature characteristic of a second polymer block, in some block copolymers, a single glass transition is observed indicating that a single phase is formed, indicating that the two polymer biocks have substantially the same giass transition temperature (e.g., a difference of about 20 X or less, about 10 or less, or both).

[78| The solution polymer according to the teachings herein may be a characterized as a random copolymer and/or having a polymer block that is a random copolymer. The random copolymer may include a primary monomer {e.g., present at a concentration of about 50 mole percent or more) and a secondary monomer randomly distributed through the polymer chain and having a concentration of less than 50 mole percent. The properties of the random copolymer will generally differ from the properties of a homopoiymer consisting entirely of the primary monomer. For example, as the amount of the secondary monomer is increased from about 0.5 mole percent to about 49.5 mole percent, the glass transition temperature of the random copolymer ma shift from a glass transition temperature characteristic of the primary monomer towards a glass transition temperature characteristic of the secondary monomer. When prepared as a random copolymer, the polymer typically has a single glass transition temperature (e.g., even when a mixture of a homopoiymer of the primary monomer and a homopoiymer of the secondary monomer, at the same concentration, exhibits multiple glass transition temperatures). A homopoiymer may have a single glass transition temperature, such as illustrated in FiG. 4A for a homopoiymer of 2-phenyM-propanol ethyl methylene malonate (Tg of about 59,4 X) and FiG. 4B for a homopoiymer of fenchyl methyl methylene malonate (Tg of about 146.9 X). A random copolymer (of monomer A and monomer B) may have one or more glass transition temperatures between the glass transitions of the corresponding homopoiymer (homopoiymer A and homopoiymer B), such as illustrated in FIG. 4C, a random copolymer of 2-phenyf-t-propanoi ethyl methylene maionate (about 50 weight percent) and fenchy! methyl methylene malonate (about 50 weight percent) having a glass transition temperature of about 88.3 °C. Preferably, the glass transition temperature of the random copolymer of monomer A and monomer 8, may differ from the glass transition temperature of both hornopoiyrner A and homopolymer 8 (e.g., ail having a weight average molecular weight of about 10,000 or more, or about 40,000 or more) by about 10 °C or more, by about 20*C or more, or by about 25 ^aC or more.

[79] The hornopoiyrner of the primary monomer may be a semicrystaiiine polymer. Typically, when a secondary monomer is added in preparing a random copolymer, the secondary monomer wiil partialiy inhibit the ability of the primary monomer to crystallize, resulting in a random copolymer having different properties from the homopolymer such as a Sower crystaSiinify, a lower f!exural modulus, a lower melting temperature, or any combination: thereof. For example, the selection of the secondary monomer and/or the amount of the secondary monomer in the random copolymer may be se!ected so that the random copolymer has a melting temperature that is reduced (i.e., relative to the homopolymer of the primary monomer) by about 5 °C o more, by about 10 °C or more, by about 15 "C or more, or by about 20 *C or more. The selection of the secondary monomer and/or the amount of the secondary monomer in the random copolymer ma be selected so that the random copolymer has a crysta!!intiiy that is reduced (i.e., relative to the homopolymer of the primary monomer) by about 0% or more, by about 20% or more, by 40% or more, or by about 60% or more.

[803 The resulting polymer may be a block copolymer including at least a first polymer block and a second polymer block different from the first polymer block. The first polymer block and the second polymer block may differ with respect to one or any combination of the following properties; peak melting temperature, final melting temperature, crystal!inity, glass transition temperature, flexura! modulus, tensile modulus, elongation at failure, ga barrier properties, or adhesion properties. For example, the first polymer block and the second poiymer block may have melting temperatures {peak melting temperatures and/or final melting temperatures) differing by about 10 °C o more, about 20 ^C'C or more, about 30 °C or more, or about 50 °C or more. If will be appreciated that one polymer block may have a melting temperature and the other poiyme block may be free of crystalline polymer so that there is no measurabie melting temperature. The first polymer block and the second poiymer block may have glass transition temperatures differing by about 10 °Ό or more, about 20 °C or more, about 30 °C or more, or about 40 or more. The first polymer block and the second polymer block may have crystaSiinifies that differ by about 10% or more, about 15% or more, about 20% or more, about 25% or more, or about 30% or more. The first poiymer block and the second polymer block may have moduli {e.g., flex modulus, tensile modulus, or both) having a ratio of about 1.5 or more, about 2 or more, about 4 or more, about S or more, or about 15 or more. The first polymer block and the second polymer block may have a ratio of elongation at faiiure and/or a ratio of tensile strength of about 2 or more, about 3 or more, about 4 or more, or about 6 or more.

[81] The degree of blockiness (i.e. the bioc iness index, or Bi) in a random copolymer may be calculated by the ratio of the concentration of clad fractions of a first monomer (e.g., a primary monomer that is a 1 ,1-disubstituted a!kene compound) added to the second monomer f{M1-M2) plus the diad fractions of the second monomer added to the first monomer f( 2- 1 ) to the theoretical concentration of diad fractions for a statistical random copolymer 2 X_Mi {1-XM . where _m is the molar fraction of first monomer:

B (f(M1- 2) + f( 2- 1 ) ) / (2 X_M1 (1-ΧΜ_Ϊ)}

8y definition a tru statistically random copolymer has a 8! of one (1.0). Blocky random copolymers will have a lower concentration of 1- 2 and 2- 1 diad fractions, and 8I will be less than 1 ,0. Biock copolymers will have very low concentrations of M1-M2 and M2- 1 diad fractions and Bl will be much less than 1 and approach zero. On the other end, alternating copolymers having X_M!≥ 0.5 will have Bi ~ 1 + (1 X«t). The concentration of the diad fractions and X_m may be measured using ^'C NM spectroscopy, using analogous peak assignments and techniques described by Yi~Ju Huange ef al. i "Random Copolymers of Propylene Oxide and Ethylene Oxide Prepared by Double Metal Cyanide Complex Catalyst", Chinese Journal of Polymer Science, 20:5, 2002, pages 453-459, incorporated herein by reference in its entirety.

{82} Preferred random copolymers have a Bi of about 0.70 or more, more preferably about 0,75 or more, even more preferably about 0,80 or more, even more preferably about 0,85 or more, even more preferably about 0.90 or more, and most preferably about 0.95 or more. Preferred random copolymers have a Bl preferabfy less than about 1+(0.8/XM , more preferably less than about 1+(0.5/x¾n), even more preferably less than about 1+(Q.25/XM ]}, and most preferably less than about 1+{0.10 x« ) where x«i is the molar fraction of primary monomer in the copolymer and Xu-t is at least 0.5.

[83] The resulting polymer may be employed in a polymeric composition including one or more additives, such as antioxidants, heat stabilizers, light stabilizers, process stabilizers, lubricants, antiblocking agents, antistatic agent, anti-fogging agents, solvents, p!asticizers, fillers, antistatic agents, coupiing agents (e.g., for the fillers), crosslinking agents, nucleating agent, anti-blocking agent, defoaming agents, pigments, colorant, f!ame retardant additives, flow aid, lubricant, slip agent and other processing aids known to the polymer compounding art. Suitable flame retardants may include halogen containing flame retardants and halogen free flame retardants. [84] Polymeric compositions may comprise one or more other fillers, such as a filler particle (e.g., fibers, powders, beads, flakes, granules, and the like). The filler particle may be a fiber (e.g., having an aspect ratio of the longest direction to each perpendicular direction that is greater than 10). The filler particle may be a particle that is not a fiber (e.g., having an aspect ratio of the longest direction to a perpendicular direction that is iess than 10, less than 8, or less than 5). The filler may be formed of an organic material and/or an inorganic material Examples of organic fillers include fillers derived from biomass and fillers derived from poiymers. inorganic fillers include, nonmetaliic materials, metallic materials, and semiconductor material. For example, the filler particle may include alumina silicate, aluminum hydroxide, alumina, silicon oxide, barium sulfate, bentonite, boron nitride, calcium carbonate (e.g., activated calcium carbonate, light calcium carbonate, or heavy calcium carbonate}, calcium hydroxide, calcium silicate, calcium sulfate, carbon black, clay, cotton flock, cork powder, diatomaceous earth, dolomite, ebonite powder, glass, graphite, hydrotalcite, iron oxide, iron metallic particles, kaolin, mica, magnesium carbonate, magnesium hydroxide, magnesium oxide, phosphide, pumice, pyrophyilite, sericite, silica, silicon carbide, talc, titanium oxide, wollastonite, zeolite, zirconium oxide, or any combination thereof. The filler particles may be present at a concentration of about 0.1 weight percent or more, about 1 weight percent o more, about 5 weight percent or more, or about 10 weigh percent or more. The filler particles may be present at a concentration of about 70 weight percent or iess, about 50 weight percent or less, about 35 weight percent or less, or about 25 weigh percent or less. The filler particles preferably have one, two, or three dimensions that are about 1 mm or less, about 0.3 mm or less, about 0.1 mm, about 50 pm or less, about 10 pm or less. The filler particles preferably have one, two, or three dimensions that are about 0.1 pm or more, about 0.3 pm or more, or about 1 pm or more.

[85] The polymeric compositions according to the teachings herein may include a plastictzer for adjusting the properties oi the final polymer for the desired use. The piasticizer may be added prior to, during, or after polymerization. For example, in certain embodiments, a suitable piasticizer can be included with the 1 ,1~disubstituted a!kene monomer. Generally, suitable p!asticizers can include plasticizers used to modify the Theological properties of adhesive systems including, for example, straight and branched chain aikyi-phthaiates such as diisonony! phthalate, diocty! phthalate, and dibutyl phthalate, as well as partially hydrogenated terpene, thoct ! phosphate, epoxy plasticizers, toiuene-suSfamide, chioroparaffins, adipic acid esters, sebaeates such as dimethyl sebacate, castor oil, xylene, l-methyl-2-pyrrolidione and toluene. Commercial plasticizers such as H8-40 manufactured by Solufia inc. (St. Louis, MO) can also be suitable.

[86] The process may include one or more steps of monitoring or otherwise measuring the conversion rate of the monomer to polymer. The concentration of the remaining monomer may be determined for example using R spectroscopy. For example, quantitative NMR spectroscopy may be employed to measure the concentration of alky!ene groups (e.g., 1-ethylene groups) remaining in the solution.

[87] The solution polymer of the current teaching may be mixed with one or more additional polymers for preparing a polymeric composition. The concentration of the solution polymer in the polymeric composition may be about 1 weight percent or more, about 5 weight percent or more, about 10 weight percent or more, about 20 weight percent o more, or about 50 weight percent or more, based on the total weight of the polymers in the polymeric composition. The solution polymer may be present in the polymeric composition at a concentration of about 100 weight percent or less, about 95 weight percent or less, or about 90 weight percent or less, or about 60 weight percent or less, based on the total weight of the polymers in the polymeric composition.

[88] The process may include one or more steps of removing some or ail of the solvent from the polymer. The process of removing the solvent may use heat, reduced pressure or both for separating the polymer from the solvent. The process of removing the solvent may include a step of filtering and/or a step of adding one or more additional liquids to the solution. For example, a non-solvent may be added at a sufficient quantity to precipitate polymer out of solution. As another example, a solvent may be added to increase the solubility of the solvent mixture and retain the polymer in the solvent solution. Other liquids may be employed for washing a precipitate, such as after a step of filtering. The process may include one or more steps of recovering unreacted monomer following polymerization. The process may include one or more steps of purifying a solvent {e.g., following polymerization and/or for use in polymerization).

[89] The process may include one or more steps of terminating {i.e., quenching) the anionic polymerization reaction. For example, polymerization can be quenched by contacting the solution with an anionic polymerization terminator. In some embodiments the anionic polymerization terminator is an acid, in some embodiments it is desirab!e to utilize a sufficient amount of the acid to render the polymerization mixture (e.g., the solution and/or th solvent) slight! acidic, preferably having a pH of !ess than 7, more preferably less than 6. Exemplary anionic polymerization terminators include, for example, mineral acids such as methanesulfonic acid, sulfuric acid, and phosphoric acid and carboxyiic acids such as acetic acid and trifSuoroacetie acid.

[90] The polymers and polymer compositions according to the teachings herein (e.g., after removing some or ail of the solvent) may have one or more rheo!ogieai properties (e.g. , melt index, melt flow rate, viscosity, melt strength, and the like) suitable for processing the polymer with known polymer processing equipment. For example, the polymer or polymer composition including 1 ,1-disubstituted aikene compounds may be processed using extrusion, co-extrusion, injection molding, insert molding, co-injection maiding, calendaring (e.g., using two or more rolls), blow molding, compression molding, thermoforming, roiling, spray coating. For example, the poiymeric material (i.e., the polymer or the polymer composition) may be fed through a processing apparatus having a screw and a barrel assembly wherein the poiymeric material is conveyed along the screw at a temperature at which the poiymeric material is at least partially in a liquid state (e.g., above any glass transition temperature and above any melting temperature),

[91] The polymers according to th teachings herein preferably adhere to one or more of the following substrates; aluminum, steel, glass, silicon, or wood. For example, when separating two substrates having the polymer placed between the substrates, the separation of the substrates may result in cohesive failure of the polymer, where some polymer remains on the surfaces of the substrates.

[92] The polymers according to the teachings herein may be employed in extruded, blow molded, injection moided, thermoformed, or compression molded articles. The polymers may be employed as an adhesive. For example, the polymers may be employed i a pressure sensitive adhesive composition. The polymers may be employed as a coating, such as a protective coating. The polymer may be employed as a primer layer over a substrate.

[93] Melting temperatures and glass transition temperatures are measured using differential scanning caiorimeiry on a sample of about 0.5-20.0 mg. The sample is heated at a rate of about 10 °C/min and then cooled at a rate of about 20 ^:C/min.

[94] The molecular weight is determined using gel permeation chromatography. GPC samples are prepared by first quenching with irif!uoroaceiic acid and then drying the polymer to remove the solvent). The dried poiymer is dissolved in tetrahydrofuran (THF). About 25 uL of the dissolved polymer solution is injected info the THF eiuent having a flow rate of 1 mL/min. Two columns with 5 micron, highly crosslinked poiystyrene/divsnyibenzene matrix particles are employed. These columns are designed to measure molecular weights of linear polymers from 700 to 2,000,000. The colum pressure is about 65 bar and the coiumn temperature is about 35 X. The eiutio time is 30 minutes. The coiumn is calibrated using PMMA standards. As such, the units for molecular weight are relative based on the standard PUMA equivalent molecular weights.

[95] Monomer conversion is calculated using quantitative HMR, A 300 MHz HMR is employed. Any residual polymerization reaction of the polymerization specimen is quenched prior to NMR analysis by adding trifluoroaeetic acid. The preferred solvent is CDCI¾as it is a polar aprotic solvent. Hexamethyldisiloxane is added as an internal standard and is suitable for these monomer compositions. The double bond intensity at about 6.45 ppm is measured to determine the concentration of unconverted monomer. This double bond is a singlet for symmetrical monomers such as diethyl methylene ma!onafe and dibufyi methylene maionate, and it is a doublet for asymmetrical monomers such as hexyl methyl methylene maionate. Four NMR scans are run on each specimen with a 20 second deiay between scans.

EXAMPLES

[96] The 1 , 1-disuhstiiuted a!kene compounds employed herein are high purit monomers, having a purity of 97 weight percent or more. The monomers either have only trace impurities and are thus stable from polymerization (anionic or free radical polymerization} or are provided with a sufficient stabilizer package {e.g., about 10 ppm methanesuifonic acid and 100 ppm mono methyl ether hydroquinone) to prevent polymerization prior to the soiution polymerization initiated for example b an activator. Unless otherwise specified, the reaction time for the polymerization reaction is about 1 hour or less.

[97] Soiution polymerization examples

[98] Example H-1

[99] Ferichyknethyi methylene maionate (FSivi) is polymerized in soiution. The solvent is tetranydrofuran. A round bottom flask is charged with about 9.0 of tetranydrofuran and about 1.0 g of the fencfiyS-methyl methylene maionate. The mixture is stirred with a magnetic stirrer for about S minutes. Tetramethy! guanidine (TMG) is then added to the flask to activate the polymerization eaction. The molar ratio of monomer (F3M) to activator (TUG) is about 1000 (i.e., 1000.1 ). The polymerization reaction is continued for about 1 hour at a temperature of about 23 "C The polymerization process is monitored by taking small ahquots of solution and quenching the reaction in the aliquot by adding an acid. After the 1 hour polymerization, a molar excess of trifiuoroaoetic acid (TP A) is added to the flask to quench {i.e., stop) the polymerization reaction. An aliquot of the soiution is taken and characterized by NMR spectroscopy. Another aliquot of the solution is analyzed by ge! permeation chromatography to measure the moiecuiar weight distribution. The soiution is then precipitated in cold (0 X) methanol. The polymer precipitates as a white powder. The precipitated polymer is filtered, dried and then characterized using Differentia! Scanning Calorimefry {DSC). NMR spectroscopy at the end of the reaction shows no measurable presence of residual monomer. The GPC indicates that the polymer has a first peak in moiecuiar weight at about 2000 and a second peak in molecular weight at about 60,000. The polymer has a polydispersity index of about 1 .43. The glass transition temperature of the polymer is about 151 ^*0. In the homopo!ymerization of fenchyl-methy! methylene maionate, by varying the reaction conditions, the purity of the monomer, the activator concentration and the reaction temperature, the moiecuiar weight distribution of the polymer may be varied between about 1 to 8 and glass transition of the polymer may be increased to be as high as about 190 "C {e.g., when weight average molecular weight is high}.

[100] Example H-2 [101] This exampie is prepared according to the method of Example H- 1. except the monomer is p-menthyl methyl methylene malonate (4 ). The resulting poiymer has a glass transition temperature of about 126 °C. The number average molecular weight is about 40,000. The homopofymerizatfoh of p-menfhyi methyf methylene malonate may result in polymer having a glass transition temperature of up to about 145 °C (e.g., by employing process conditions that result in higher weight average molecular weight).

[ 02] Exampie H-3 is a poiymer of diethyl methylene malonate prepared in solution. About 18 g of tetrahydrofuran solvent is added to a HDPE bottle having a PTFE coated magnetic stir bar at a temperature of about 23 ^*C and ambient pressure. The bottle is placed on a magnetic stir plate using a mixing speed of about 800-1000 rpm. About 2 grams of diethyl methylene malonate monomer (DEMM) is added to the HDPE bottle and mixed to form a solution of the monomer in the solvent. After about 5 minutes, about 72 microliters of tetramethyiene guanidine (TMG) {at 1 weight percent) in methylene chloride is added to the monomer solution in the HDPE bottle. This corresponds to a molar ratio of monomer (DEMM) to activator {TMG) of about 2000:1. After a 1 hour reaction time, the polymerization is terminated by adding about 0.2 ml of triftuoroacetic acid. The poiymer is recovered from the solvent using the method described above for Exampie H-1. The molecular weight distribution of the resulting poiymer is measured using gel permeation chromatography and the results are shown in Table 1 ,

[103] Example H-4 is prepared according to the method of preparing Example H-3, except the amount of the activator is reduced to about 36 microliters, corresponding to a moiar ratio of monomer to activator of about 4000:1. Example H-5 is prepared according to the method of preparing Example H-3, except the mount of the activator is reduced to about 18 microliters, corresponding to a molar ratio of monomer to activator of about 8000:1. Exampie H~8 is prepared according to the method of preparing Exampie H-3, except the mount of the activator is reduced to about 9 microliters, corresponding to a molar ratio of monomer to activator of abou 16000:1. Example H-7 is prepared according to the method of preparing Example H-3_S except the mount of the activator is reduced to about 4.5 microliters, corresponding to a moiar ratio of monomer to activator of about 32000:1 .

[104] Activator Examples

[105] Example A- 1

[106] A weak base may be employed to initiate the anionic polymerization of a 1 ,1- disubstituted a!kene compound, in example A-1 , an activator solution Is prepared by dissolving 0.13 g of potassium benzoate and 0.428 g of a crown ether (18-crown 6) in 10 mL of dichioromefhane. The molar ratio of potassium benzoate to the crown ether Is about 1 :2. it is believed that crown ethers may assist in soiubiiszing the potassium benzoate in DCM. The activator solution is used for activating the solution polymerization of diethyl methylene maionate (about 2 g) in tetrabydrofuran (about 18 g). About 138 microliters of the activator solution is added to initiate the polymerization. The molar ratio of monomer to activator is about 1000:1. Polymerization: js allowed to continue for 24 hours at about 23 "C, and then quenched with trifSuoroaeetic acid. The resulting polymer is further diluted with ietrahydrofuran for measuring the molecular weight distribution by gel permeation chromatography. The polymer has a weight average molecular weight of about 405,700 and a number average molecular weight of about 198,000.

[107] Example N-1. Example N-1 is prepared by polymerizing diethyl methylene maionate at low temperature. The polymerization is performed at about -78 *C in a Schienk fiask apparatus. AS! glassware is thoroughly dried by repeatediy pulling vacuum and purging with nitrogen. Freshly distilled diethyl methylene maionate monomer is stored in a sealed polypropylene bottle and degassed under vacuum prior to use. The solvent, ietrahydrofuran, is taken directly from a sealed bottle without exposing to air or moisture. The activator is secondary butyl lithium and is provided as a 1.5 M solution in cyclohexane. The reaction temperature is maintained using a dry ice acetone freezing mixture. About 1 g of the diethyl methylene maionate is dissolved in about 9 g of ietrahydrofuran in a round bottom flask under a nitrogen environment. After about 5 minutes, the activator solution was added {about 5 microliters), resulting in a molar ratio of monomer fo activator of about 1000;1. The reaction was continued for about 20 minutes and then terminated by adding methanol and frifiuoroacetic acid. Aliquots are removed at about 2 minutes, 6 minutes, 10 minutes, and 20 minutes polymerization time. The molecular weight distribution of each aitquot is measured using ge! permeation chromatography. The results are given in Table 2.

[ 08] Example N-2 [109] The anionic polymerization of 1 ,1-disubstituted a!kenes may be characterized as a Iving polymerization. In example N-2, the process of Example N-1 is repeated except the amount of diethyl methylene malonate initially added to the tetrahydrofuran solvent is about 0.2S g. During the polymerization reaction, a small aliquot Is removed every 2 minutes and an additional 0.25 g of the monomer is added to the reaction flask. The process is continued for about 10 minutes, when the polymer begins to precipiiate out of the solvent. The amount of activator employed is selected so that the molar ratio of the amount of monomer added in the first injection {i.e., 0.25 g) to the activator is about 1000: 1. The molecular weight, measured by gel permeation chromatography increases nearly linearly:

[1 10] Example N-3

[111] Example N-3 is prepared the same as Example N-2 except the amount of the activator is increased so that the molar ratio of total monomer to activator is about 100:1. Again, the polymer continues to grow with each additional charge of monomer:

[112] Copolymers / Random Copolymers

[1 13] Example R-1 , Example R-1 is a random copolymer prepared using solution polymerization. The method used for Example H-3 is used with the following changes: (1 ) the 2 g of DEivlivl was replaced with 1 g of (P3EV5) and 1 g of (H3 ); and (2) the amount of the 1 percent TMG activator solution is adjusted so that the molar ratio of the tota! monomer to the activator is about 1000:1 , The polymerization reaction is at about 23 ^*C. The polymer is characterized using gel permeation chromatography and differential scanning calorimetry. The resulting polymer is a random copolymer having a singie glass transition temperature of about 27.5 ^BC. The number average molecular weight is about 7,104 daltons, and the weight average molecular weight is about 16,343 daltons, resulting in a polydispersity index, PDi, of about 2.3,

[114] Example R-2, R-3, and R-4 are random copolymers including a first monomer thai is a 1 , -disubstituted aikene monomer and a second monomer that is a second 1 ,1- disubstituted aikene monomer. Example R-2, R-3, and R-4 are prepared using the method of Example R-1 , except (1 ) the amount of tetrahydrofuran is about 9 g, and (2) the monomers are replaced with hexyi methyl methylene malonate (HM3) and diethyl methylene malonate {DEM ) with a ratio of HM3 to DEMM of 75;25, 50:50, and 25:75, respectively, and a total of 1 g of monomer. The polymerization is continued for about 1 hour at about 23 "C, while mixing. After quenching with trifluoroaeetic acid, the resulting polymer is characterized by gei permeation chromatography, and MR spectroscopy. After isolating the polymer by precipitation, filtration and drying the polymer is characterized by differentia! scanning caiorimetry.

[1 15] Example H-8, is an homopoiymer prepared according to the method of Example R-2, except the monomer is 1 g of hexyi methyl methylene maionate monomer. The results for examples R-2, R-3, R-4, and H-S are shown in Table 3. These examples each have a single glass transition temperature suggesting thai R-2, R-3, and R-4 are random copolymers. jfaibie 3. Random Copolymers of hexyi methyi methylene maionat (H3M) and diefhy! methylene maionate (DEMM).

[1 16] Block Copolymer

[1 17] Example B-1 is a block copolymer having four polymer blocks including 2 polyme blocks (A blocks} of a first homopoiymer and 2 polymer blocks (8 blocks) of a second homopoiymer. The block copolymer has the structure: A-B-A-B, where each A and 8 is a polymer h!ock. Block A consists of 2-phey!propy! methyl methylene maionate. Block 8 consists of hexyi methyl methylene maionate. A SchSenk fiask is passivateei with an acid solution, rinsed with methylene chloride, and dried in an oven. About 18 g of tetrahydrofuran: is placed in the Schienk fiask. About 0,25 g of monomer A is then added to the flask. The flask is then capped with a rubber septa and submerged halfway in a bath of acetone and dry ice having a temperature of about -78 X. Vacuum was puled on the flask and then allowed to back fi!! with nitrogen. The vacuum / nitrogen back fi!! is repeated at least 3 times. The solution is mixed using a PTFE coated magnetic stir bar. Using a gas-tight microliter syringe, sec-butyliithium is added as an activator. The amount of the activator is chosen so that the molar ratio of the initial monomer to the activator is about 1000:1 . After reacting for about 5 minutes, a smail aliquot is removed. This aliquot is quenched with trifiuoroacetic acid and the molecular weight distribution of th aliquot is measured using gei permeation chromatography. The aliquot is a!so characterized using NMR spectroscopy. The polymerization is then continued by injecting about 0.25 g of monomer 8 into the fiask using a syringe and reacting for about 5 minutes. A second aliquot is then removed from the flask before adding a third amount of monomer {0.25g of monomer A) into the fiask using a syring and reacting for about 5 minutes. A third aiiguot is then removed from the flask before adding a fourth amount of monomer (0.25g of monomer B) into the fiask using a syringe and reacting for about 5 minutes, A fourth aliquot is then removed. Each aliquot is treated as the first aiiquot {i.e., quenched and then characterized by GPC and NMR). The resuits of each aliquot are shown in Table 4, The final: block copolymer is isolated and characterized using differential scanning caiorimetry.

[118] Example S-1 is prepared according to the method of Example H-7 using tetrahydiOfuran as the solvent. The resulting poiymer has a number average molecular weight of about 2,000,000 daltons. Exampie S-2 is prepared according to the method of Example S-1 , except the solvent is heptane. The resulting poiymer has a number average molecular weight of about 500,000 daltons. Example S-3 is prepared according to the method of Example S-1 , except the soivent is toluene. The resulting polymer has a number average molecular weight of about 200,000 daitons. Exampie S~4 is prepared according to the method of Exampie S-1 , except the soivent is dimethoxy ethane. The resulting poiymer has a number average molecular weight of about 700,000 daitons. Example S-5 is prepared according to the method of Exampie S-1 , except the solvent is dichioromethane. The resulting poiymer has a number average mo!ecuiar weight of about 150,000 daitons,

[119] Exampie P-1 and Exampie P-2 are homopolymers prepared using the method of Example H-1 , except the monomer is p-menthy! methyl methylene maionate (4M) and the molar ratio of monomer to activator is about 100:1 for Exampie P-1 and about 1000:1 for exampie P-2. The monomer employed in exampie P-1 has a purity of about 94.1 weight percent and the monomer employed in exampie P-2 has a purity of about SS.23 weight percent. Exampie P-1 has a number average molecular weight of about 6,700 daltons, a weight average molecular weight of about 17,400 daltons, a polydispersity index of about 2.80 and a glass transition temperature of about 83 "C, Example P-2 has a number average molecular weight of about ,451 ,800 daitons, a weight average molecular of about 2,239,300 dal tons, a poiydispersity index of about 1.62, and a glass transition temperature of about 145 "C.

[120] Example P-3 and Exampie P-4 are homopolymers prepared using the method of Example H-1 , except the monomer is fenohyi methyl methylene maionate (F3M) and the molar ratio of monomer to activator is about 100: 1. The monomer employed in exampie P-3 has a purity of about 92,8 weight percent and the monomer employed in exampie P-2 has a purity of about 98.8 weight percent. Example P-3 has a weight average moiecuiar weight of about 40,300 daitons and a giass transition temperature of about 136 ⁼C. Exampie P-4 has a weight average moiecuiar of about 290,800 daitons and a giass transition temperature of 190°C.

[121] Exampie X-1 , X-2, X-3, and X-4 are ail homopoiymers prepared using diethyl methylene malonate. The poiymers are prepared in solution using tetrahydrofuran as the soivent and using monomer from the same batch. Examples X-1 , X~2, and X-3 are prepared in a small scale-reactor to produce about 1 g of polymer. Example X-4 is prepared in a iarger reactor for preparing 450 g of polymer. The processing conditions for Examples X-1 , X-2, X- 3, and X-4 are the same, inciuding the same ratio of monomer to activator, the same reaction time, and the same ambient conditions. Exampie X-4 is prepared in an 8L round bottom flask and 4.05 kg of solvent was used. After adding the monomer, the flask solvent and monomer are mixed at 500 rpm to form the solution. About Q.T03 mi of pure T G is added as the activator while mixing is continued during the 1 hour reaction time. After 1 hour, the reaction was terminated with TFA and the polymer was isolated using the method of Exampie H-1 (i.e. precipitated in co!d methanol). Over the first 15 minutes, the reaction temperature increased by about 19 "C when preparing Exampie X-4. The resuits are shown in Table 5.

[122] The number average moiecuiar weight is generally expected to be highest when using a polar aprotic solvent Lower number average molecular weights are generally expected to be obtained when using a nonpo!ar solvent.

[123] Reference Signs from Drawings

[124] 10 Solution polymerization system

[125] 12 Soivent

[126] 14 Monomer

[127] 16 Activator

[128] 26 Poiymer

[129] 30 Illustrative steps inc!uded in a solution polymerization process

[ 30] 32 Step of forming a soiution inciuding one or more monomers and a solvent

[131] 34 Step of adding an activator to begin a polymerization reaction [132] 36 Step of propagating the polymer by an anionic polymerization reaction

[133] 37 Optional step of adding one or more monomers and/or continuously feeding one o more monomers {e.g., after previously added monomer has been consumed).

[134] 38 Optiona! step of quenching the polymerization reaction

[135] 40 About 6.45 ppm on the spectrograph (corresponding to reactive double bond)

[136] 42 About 0 ppm on trie NMR spectrograph ~ internal reference

[137] 50 GPC peak

[138] 51 GPC peak area

[139] 52 Weight Average Molecular Weight ( w)

[140] 54 Calibration curve (molecular weight v. retention time) based on PM A standards

[141] 56 Low limit

[142] 58 GPC Curve

Claims

CLAIMS What is claimed is:

1. A process comprising:

anionicaiiy polymerizing at ieast one monomer including a 1 ,1-disubstituted aikene compound in solution.

2. The process of claim 1, wherein

the at least one monomer includes two or more monomers, and the process comprises the steps of;

i) mixing the two or more monomers and a solvent; wherein the two or more monomers inciudes a first monomer which is a 1 ,1-disubstituted aikene compound and a second monomer different from the first monomer (e.g., a different 1 ,1-disubsiituied aikene compound);

ii) adding an initiator;

fit) reacting the initiator with one of the two or more monomers (e.g., with the first monomer or with the second monomer) for initiating the anionic polymerization of the two or more monomers; and

iv) anionicaiiy polymerizing the two or more monomers to form a polymer having a weight average molecular weight of about 3000 da!tons or more, including both the first monomer and the second monomer.

3. The process of claim 1 or 2, wherein the polymer is a random copolymer.

4. The process of c!aim 1.. wherein

the at least one monomer includes a first monomer; and

the process comprises the steps of;

I) mixing at least the first monomer and a solvent to form a solution including the first monomer and the solvent; wherein the first monomer is a first 1 ,.1-disubstitufed aikene compound;

ii) adding an initiator;

Hi) anionicaiiy polymerizing the first monomer in the presence of the solvent to form a first polymer block including the first 1 ,1-disubstituted aikene compound and having a weight average molecular weight of about 1000 da!tons or more (e.g., having a number average molecular weight of about 1000 da!tons or more), wherein the first polymer block has a reactive chain end;

iv) after polymerizing the first polymer block, adding a ieast a second monomer to the solvent to form a solution including the second monomer and the solvent, wherein the second monomer is different from the first monomer (e.g., the second monomer is a second I , 1-disubstituted alkene compound different from the first 1.1~disibusfituted alkene compound);

v) reacting the second monomer to the reactive chain end of the first polymer block: and vi) antontcal!y polymerizing the second monomer to form a second polymer block including the second monomer and having a weight average molecular weight of about 1000 daltons or more (e.g., having a number average molecular weight of about 1000 daltons or more), wherein the second polymer block has a reactive chain end, and the composition of second polymer biock is different from the composition of the first polymer block.

5. The process of c!aim 4 wherein the second polymer block has a different glass transition temperature than the glass transition temperature of the first polymer block,

6. The process of claim 4 or 5, wherein the second poiyrner block and the first polymer block have different concentration of monomers.

7. The process of any of claims 1 through 6, wherein the polymer is a linear polymer.

8. The process of any of claims 1 through 7, wherein the concentration: of the first 1 ,1- disubstituted alkene compound is about 30 weight percent or more, based on the iota! weight of the poiyrner.

9. The process of any of claims 1 through 8, wherein the process includes a step of terminating the polymerization reaction,

10. The process of any of claims 1 through 9, wherein the process includes a step separating the poiyrner from the solvent.

I I . The process of any of claims 1 through 10, wherein the process includes a step of drying the polymer.

12. The process of any of claims 1 through 1 , wherein the process includes a

polymerization temperature of about 40 °C or less.

13. The process of an of claims 1 through 12, wherein the polymerization solution includes a base or a compound capable of forming a base or a nue!eophile that can initiate polymerization of the monomer.

14. The process of any of claims 2 through 13, wherein the ratio of the first monomer to the second monomer is from about 5:95 to about 95:5.

15. The process of any of claims 1 through 14, wherein the resulting polymer is

characterized by a weight average molecuia weight or a number average molecuia weight from about 3,000 to about 3,000,000 daltons; a poiydispersity index from about 1 to about 11 (e.g., from about 1 to about 5); or both.

16. The process of any of claims 4 through 15, wherein the resulting polymer is a biock copolymer including a first block having a first glass transition temperature and a second polymer block having a second glass transition temperature, wherein the first glass transition temperature and the second glass transition temperature differ by about 20 "C or more.

17. The process of claim 16, wherein the first g!ass transition temperature is about 40 X or more (or 60 X or more, or 80 X or more, or 100 X or more, or 120 or more), and the second a glass transition temperature is !ess than the first g!ass transition temperature (e.g about 60 X or less, or 40 or less).

18. The process of any of ciatms 1 through 1?, wherein the resulting polymer has a polydispersity index of about 3,5 or less (e.g., about 2 or less, about 1 ,5 or less, about 1.3 or !ess, or about 1 ,2 or less),

19. The process of any of claims 1 throug 18, wherein the molar ratio of the first monomer to the activator is about 50,000:1 or less, (e.g., about 20,000:1 or less).

20. The process of any of ciatms 1 through 19, wherein the molar ratio of the first monomers to the activator is about 10:1 or more (e.g., about 50:1 ) or more,

21. The process of any of claims 1 through 20, wherein

the resulting polymer has a poiydispersity index of about 3.5 or less; and

the mo!ar ratio of the first monomer to the activator is from about 10:1 to about 50,000:1.

22. The process of any of ciatms 1 through 21 , wherein the one or more monomers includes one or more monomers selected from the group consisting of methyl propyl methyiene malonate, dihexyi methyiene maionate, di-isopropyl methyiene malonate, butyl methy! methylene malonate, ethoxyethyl ethyl methyiene malonate, methoxyethyl methyl methylene malonate, hexy! methyl methylene maionate, dipentyi methyiene maionate, ethyl pentyi methylene maionate, methyl pentyi methyiene malonate, ethyl ethyimethoxy methyiene malonate, ethoxyethyl methyl methyiene malonate, butyl ethyl methylene maionate, dibutyS methylene malonate, diethyl methylene maionate (DE ), diethoxy ethyi methyiene malonate, dimethyl methyiene malonate, di-N-propyi methylene maionate, ethyi hexyl methylene maionate, fenchy! methyl methylene malonate, menthy! methyl methyiene malonate, 2-phenyipropyi ethyl methylene maionate, S-phenyipropyie methylene maionate, and dimethoxy ethyl methylene malonate,

23. The process of any of claims 1 throug 22, wherein

the at !east one monomer inc!udes a first monomer, and

th process comprises the steps of:

i) mixing the first monomers and a solvent;

it) adding an activator- tit) reacting the activator with one of the one or more monomers for initiating the anionic polymerization of the one or more monomers; and

iv) antontcai!y polymerizing the one or more monomers to form a polymer having a weight average molecular weight of about 2000 daltons or more {e.g., having a number average molecular weight of about 2000 daltons or more), the polymer including the ftrst monomer, wherein the first monomer is provided as a high purity monomer having a purity of about 95 weight percent or more (preferabl having a purity of about 97 weight percent or more, even more preferably having a purity of about 99 weight percent or more), based on the total weight of the high purity monomer.

Claim 24, The process of any of ciaims 1 through 23, wherein the process includes a step of depositing a solution onto a substrate, the solution including a polymer resulting from the polymerization step; and

a step of evaporating some or all of the solvent so thai the substrate is partially or entirely coated with a layer of the polymer.

Claim 25, A pressure sensitive adhesive prepared according to the method of any of claims 1 through 24.

Claim 26. A polymer prepared according to the method of any of claims 1 through 24.