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Polymerization Kinetics of Photocurable Acrylic Resins

EWA ANDRZEJEWSKA, MACIEJ ANDRZEJEWSKI


Poznan University of Technology, Institute of Chemical Technology and Engineering, Pl. Sklodowskiej-Curie 2,
60-965 Poznan, Poland

Received 25 March 1997; accepted 25 August 1997

ABSTRACT: The polymerization kinetics of photocurable compositions based on an ep-


oxyacrylate oligomer and three analogous diacrylate monomers were investigated. The
effects of the oligomer-to-monomer ratio, curing conditions, and monomer structure
were considered. The polymerization is characterized by a synergistic effect observed
in a wide temperature range and occurring for the polymerization rate both in air and
Ar and for final conversions in air. The final conversion in Ar is determined by viscosity
of a formulation. The presence of a heteroatom (S or O) in the ester group of the
reactive diluent is beneficial for the polymerization course, especially in air atmosphere.
The best results were obtained for the sulfur-containing monomer. q 1998 John Wiley &
Sons, Inc. J Polym Sci A: Polym Chem 36: 665673, 1998
Keywords: epoxyacrylate; diacrylates; photopolymerization; kinetics; synergistic ef-
fect; temperature effect; heteroatom effect

INTRODUCTION While final film properties result from the


blend of ingredients, each compound lends its spe-
Photosensitive resins that polymerize readily un- cial character to the coating. The oligomers, gen-
der intense UV radiation are being increasingly erally acrylate functional, impart properties asso-
used in various sectors of applications, mainly in ciated with their basic structure. Typical commer-
the coating industry, the graphic arts, and micro- cial oligomers are acrylated urethane, polyesters,
electronics. UV curing technology allows the pro- silicones, and epoxides. Acrylated epoxides, for in-
duction of high resolution relief images that are stance, impart chemical resistance, hardness, and
required for the manufacture of integrated cir- adhesive strength. The monomers, also typically
cuits or printing plates, as well as to achieve fast acrylate functional, provide viscosity control, as
hardening of clear or pigmented coatings, adhe- well as impart properties based on their structure.
sives, and composites.1 3 Photocurable composi- Highly functional monomers (containing at least
tions are used for the surface protection of all kind two double bonds) increase crosslink density of
of materials (metals, plastics, glass, paper, wood, the polymer, increasing in this way hardness of
fabrics, etc.) by fast-drying varnishes, paints, or the coating. Alkoxylated monomers can reduce
printing inks as well as in dentistry.1,2,4 Most of- surface tension, enhance the wetting and adhe-
ten these photosensitive resins consist of multi- sive character, but can also reduce water resis-
functional oligomers and monomers that polymer- tance and toughness.2,5 Recently studied sulfur-
ize to form highly crosslinked polymer network, containing monomers improve thermo-oxidative
additives of various types, and a photoinitiator stability 6 reduce solvent swellability and mois-
that yields reactive initiating species upon UV ex- ture absorption 7 as well as increase refractive in-
posure. dex 8 of the coating.
However, the nature of the resultant polymer
may depend not only on the properties of the reac-
Correspondence to: E. Andrzejewska
Journal of Polymer Science: Part A: Polymer Chemistry, Vol. 36, 665673 (1998)
tive components but also on cure kinetics. Gener-
q 1998 John Wiley & Sons, Inc. CCC 0887-624X/98/040665-09 ally, the rate of polymerization depends first of
665

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666 ANDRZEJEWSKA AND ANDRZEJEWSKI

all on the reactivity of the functional groups, on (b) curing conditions (temperature and atmo-
their concentration and on the viscosity of the sphere), and
resin, whereas the chemical structure and func- (c) monomer structure (the presence and type
tionality of both the monomer and the oligomer of the heteroatom in the ester group).
determine the final degree of polymerization.9 For
a given formulation, the polymerization kinetics
depend on reaction conditions, i.e., atmosphere, EXPERIMENTAL
temperature, light intensity, photoinitiator con-
centration, etc.2,10,11 Thus, to obtain the best phys-
Synthesis and characteristics of the monomers
ical and mechanical properties of the polymeriza-
are described elsewhere.7 Chemical formulae of
tion product one must not only consider the mate-
the acrylates used are given in the following:
rials used, but also the conditions under which the
polymer was formed. These reaction conditions,
along with the type of reactant system chosen,
will completely control the polymerization rate
and conversion of double bond in the system. The
conversion, in turn, will determine the mechani-
cal, physical, and wear properties of the material where: n 0.1514
formed.
The polymerization of multifunctional mono-
mers shows a complex behavior.2,4,10,11 One of the
most characteristic features is autoacceleration,
i.e., the increase in rate of polymerization despite
the consumption of monomer, which occurs due
to extremely restricted diffusion of radicals in the
highly crosslinked polymer. Another process, au-
todeceleration occurs because the propagation
eventually becomes diffusion controlled along
with the termination. Both these processes lead
to the appearance of a maximum polymerization
rate. Polymerization is continued until it stops X|S: TEDA
from vitrification. Depending on the monomer sys- X|O: OEDA
tem and the reaction conditions by which the sys-
tem was polymerized, the polymerization typi- X|CH2 : PDA
cally ceases before complete conversion of the
functional groups.4 The polymerization kinetics were monitored by
The aim of this work was to investigate the a differential scanning calorimeter (DSC 605 M,
polymerization kinetics of photocurable composi- UNIPAN-TERMAL, Warsaw, Poland) equipped
tions based on an epoxyacrylate oligomer (EPA) with a lid especially designed for photochemical
and three analogous diacrylate monomers: 2.2 *- measurements and computer-aided data analysis
thiobisethanol diacrylate (TEDA), 2,2 *-oxybis- software. The initiator, 2,2-dimethoxy-2-phenyl-
ethanol diacrylate (OEDA), and pentane-1,5-diol acetophenone (Irgacure 651t from CibaGeigy,
diacrylate (PDA). Due to a variety of technologi- Basel) was applied in concentration 0.01 mol/kg.
cal curing conditions (air atmosphere or an inert Accurately weighed ( 10 mg) samples of the pho-
gas blanketing, often elevated temperatures due tocurable composition were polymerized in 6.8
to large amounts of heat emitted by UV lamps), mm diameter open aluminum DSC pans. When
the polymerization kinetics were followed in the polymerization was carried out in an inert atmo-
presence and in the absence of atmospheric oxy- sphere, the sample was allowed to equilibrate in
gen and at a wide temperature range. the apparatus under argon (0.0005% O2 ) for 10
The results obtained in this work are discussed min at the chosen polymerization temperature. A
in terms of the effects of the following factors on medium-pressure mercury lamp equipped with a
the polymerization kinetics: glass filter was used for the irradiation. The trans-
mitted light was in the range of 310400 nm with
(a) oligomer to monomer ratio; lmax at 366 nm. The incident light intensity at the

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PHOTOCURABLE ACRYLIC RESINS 667

Table I. The Concentration of Double Bonds in the of these parameters obtained for the polymeriza-
Compositions and in the Components tion of individual formulations.
The exemplary comparison of the polymeriza-
Concentration of Double Bonds tion courses of OEDA, EPA, and their mixtures
(mol/kg)
at 507C in Ar is given in Figure 1(a) and (b). As
can be seen, the formulations containing mixtures
In
Compositions of the oligomer and the monomer polymerize
much faster (higher R pmax and shorter time needed
EPA to to reach R pmax ) than individual components. The
Monomer Molar lowest reactivity of the oligomer results from its
Ratio high viscosity (as high as 10 5 of that of mono-
mers), which restricts diffusional mobility of EPA
Components In Components 1 : 2.5 1:1 molecules. Such dependence is typical for lower
and medium polymerization temperatures and for
TEDA 8.70 6.35 5.28 all the monomers, both in Ar and air. At higher
OEDA 9.35 6.59 5.40
temperatures, about 807C, this dependence is of-
PDA 9.43 6.62 5.41
ten disturbed by an increase in rates of processes
EPA 3.80
parallel to propagation (e.g., degradation, chain
transfer, oxidation, etc.). The plots of p f and
R pmax vs. polymerization temperature obtained for
sample pan position was measured to be 1.8 mW/ Ar and air atmospheres for the monomers, oligo-
cm2 (by the carbon black method). mers, and their compositions are presented in Fig-
For calculations, a value for the heat of poly- ures 25. The values of p f and R pmax for polymer-
merization DH0 86 kJ/mol 7 (per one double ization carried out in air are lower than those
bond) was taken. Conversion at the time at which for polymerization in Ar due to the well-known
the polymerization rate decreased to 0 (ca. 20 inhibitory effect of atmospheric oxygen. However,
min.) was taken as the final conversion. The DSC it is worthy to note that detrimental effect of oxy-
data obtained were analyzed for the corrected gen is much less pronounced in the polymeriza-
base line. tion of the oligomer, which is associated with re-
duced oxygen diffusion to the highly viscous me-
dium.
RESULTS Registered by DSC, overall heat effect results
from several various processes, besides the most
The most often used in practical applications importantpropagation, also from those men-
oligomer-to-monomer ratio varies between 50 : 50 tioned above, like degradation, depolymerization
to 70 : 30 by weight. Both these ratios were chosen or oxidation (H-abstraction is a zero-enthalpy pro-
to formulate the oligomer and monomer mixtures cess 2 ). The contribution of these processes to the
used in this work for the investigation of the cure overall heat flow (and heat evolved) depends to a
kinetics. Thus, the compositions contained: (a) high degree on the state of the polymerizing sys-
oligomer and monomer in weight ratio 50 : 50, tem, mainly on the conversion degree of double
which corresponds to molar ratio 1 : 2.5; and (b) bonds. For this reason the discussion of the re-
oligomer and monomer in weight ratio 70 : 30, sults also includes the temperature dependence of
which corresponds to molar ratio 1 : 1. the polymerization rate during an early reaction
The concentration of double bonds in the com- stageat 3% of double bond conversion ( R 3p , Figs.
positions and in the components are given in Ta- 6 and 7). The lack of some points related to bound-
ble I. The polymerization was carried out isother- ary temperatures on these plots result from the
mally in the temperature range from 30 to 1007C fact that corresponding R pmax values were reached
in the presence or absence of atmospheric oxygen. at conversions lower than 3%.
The most important parameters characterizing Another factor that influences the results ob-
the cure kinetics of multifunctional monomers tained at the highest temperatures is possible evap-
are: the rate at peak maximum (maximum poly- oration of the monomers during the polymerization.
merization rate R pmax ) and final degree of double For instance, whereas volatility of PDA at 807C is
bond conversion (p f ). The discussion of the re- negligible, at 1007C the weight loss after about 20
sults in this work is based mainly on the values min can reach several percent. This may somewhat

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668 ANDRZEJEWSKA AND ANDRZEJEWSKI

Figure 1. Polymerization of EPA, OEDM, and their mixtures in 1 : 1 and 1 : 2.5


oligomer to monomer molar ratios in Ar at 507C: (a) reaction rate profiles; (b) double
bond conversion profiles.

lower the parameters obtained, especially p f values. increased reactivity, which is manifested by a sub-
On the other hand, EPA is completely nonvolatile stantial increase in the polymerization rates, both
in the temperature range studied. in air and Ar, in comparing to Rp values of the
individual components. The enhanced reactivity
DISCUSSION of such compositions is reflected also by the in-
creased final conversions achieved in air atmo-
The Influence of the Oligomer-to-Monomer Ratio
sphere (not in Ar). The best results were obtained
As was mentioned above, the formulations based for equimolar mixtures of EPA and reactive dilu-
on mixtures of EPA and the monomers show an ents. When the registered effect of a mixture of
two or more components is not additive but
greater than would be expected from the additiv-
ity law, synergism between the components of the
mixture is said to occur.12 This synergistic effect
is illustrated by Figure 8, which shows the de-
pendencies of R pmax and p f at 707C on the composi-

Figure 2. Temperature dependence of final conver-


sions for polymerization in Ar. ( h) TEDA, ( s) OEDA,
(n) PDA, ( L) EPA. Open symbols and dashed lines
denote monomer and oligomer polymerizations; filled
symbols denote polymerization of compositions con-
taining corresponding monomer; solid lines denote po-
lymerization of compositions with 1 : 2.5 oligomer-to-
monomer molar ratio, and dotted lines denote polymer-
ization of compositions with 1 : 1 oligomer-to-monomer Figure 3. Temperature dependence of final conve-
molar ratio. sions for polymerization in air. Symbols as in Figure 2.

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PHOTOCURABLE ACRYLIC RESINS 669

Figure 4. Temperature dependence of maximum po- Figure 6. Temperature dependence of the polymer-
lymerization rates in Ar. Symbols as in Figure 2. ization rates at 3% of double bond conversion in Ar.
Symbols as in Figure 2.

tion of EPA / monomer mixtures. The appearance


of a synergistic effect was also shortly mentioned pends on the crosslink density (the lower initial
by other authors for the polymerization rate of double bond concentration, the higher network
mixtures of an epoxyacrylate oligomer and mo- mobility), nevertheless, the diffusional limita-
noacrylates containing heterocyclic structures in tions caused by high initial viscosity of the formu-
their ester groups.13 lation are the crucial factors in this case.
Synergistic effect does not occur in the case of Synergistic effect is observed also for the poly-
final conversion for the polymerization carried out merization rate at low degrees of conversion ( R 3p
in Ar. That means that in the inert atmosphere, Figs. 6 and 7). In Ar it exists only to about 607C
the oligomer-to-monomer ratio determines the po- due to fast increase in R 3p of EPA with tempera-
lymerization rate, whereas the final conversion is ture that results from very strong temperature
determined by viscosity of a formulation: the dependence of the oligomer viscosity (high activa-
lower viscosity, the higher conversion. The mobil- tion energy of viscosity equal to 129 kJ/mol 14 ). At
ity of the polymer network plays a dominant role 907C, R 3p value of EPA reaches the R 3p value ob-
in determining the value of p f . Although it de-

Figure 7. Temperature dependence of the polymer-


Figure 5. Temperature dependence of maximum po- ization rates at 3% of double bond conversion in air.
lymerization rates in air. Symbols as in Figure 2. Symbols as in Figure 2.

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670 ANDRZEJEWSKA AND ANDRZEJEWSKI

Figure 8. Synergistic effect in the polymerization of EPA and monomer mixtures at


707C in Ar and air: (a) maximum polymerization rate; (b) final conversion. (j) TEDA,
(l) OEDA, ( m) PDA.

tained for equimolar mixture of the reactants, in- sional limitations, but simultaneously reduces
dicating, that under conditions where diffusion of possible interactions between EPA and monomer
reactants is not strongly restricted (low conver- molecules.
sion, reduced viscosity) the polymerization rate The existence of an association may explain the
tends to increase with the oligomer content in the occurrence of the synergistic effect in the case of
composition. final conversions in air. The close neighborhood
As the reaction proceeds, the network density of the interacting comonomers causes substantial
and viscosity of the polymerizing system increase reduction of the inhibitory effect of atmospheric
and near R pmax the propagation and termination oxygen due to lowering of oxygen diffusion, which,
become diffusion and reaction diffusion con- in turn, enables the polymerization to proceed to
trolled, 15,16 respectively. Because the strongest higher conversions. This effect, observed to about
diffusional limitations occur for EPA homopoly- 907C, may find practical importance in production
merization, its R pmax values are the lowest in the of protective coatings cured in air atmosphere.
whole temperature range (Fig. 4). Very high vis- Thus, the 1 : 1 composition gives the optimum
cosity of EPA results from hydrogen bonding due effect of increasing the polymerization rate at low
to the presence of hydroxy group.14 The enhanced and medium polymerization temperatures and re-
reactivity of the oligomer / monomer mixture duction of oxygen diffusion in air.
needs a good compatibility between the reactants,
for example, solubility, which is usually facili-
The Influence of Temperature
tated by intermolecular interactions. One may ex-
pect that a type of intermolecular interactions As can be seen in Figures 2 and 4, the values of
may exist also between oligomer and monomer R pmax and p f for the polymerization in Ar increase
molecules (C|O and OH groups), especially at with temperature up to about 60807C, de-
equimolar oligomer-to-monomer ratio. This, to- pending on formulation, but further grow with
gether with the reduced viscosity of the formula- temperature is hampered, and even a declining
tion, would favor an increase in the polymeriza- tendency is observed in some cases.
tion rate. It was found, that biunsaturated acrylic Although evaporative loss of the monomers
monomers are able to form associates and that may complicate the interpretation of the results
their polymerization rate is sensitive to intermo- obtained at the highest temperatures (from about
lecular interactions.17 Further increase in the 907C), the main reason of such polymerization
monomer content continues to decrease diffu- behaviors must be chemical in nature, most prob-

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PHOTOCURABLE ACRYLIC RESINS 671

ably chaintransfer reaction and thermal degra- The difference between the strong growing
dation or depolymerization, 7,14 16,18 which rates temperature tendency of R pmax of monomers and
increase with temperature. The existence of a pla- EPA in air and its tendency to reach a plateau
teau region on the final conversiontemperature in Ar in the polymerization above 807C may be
plots suggests a topologically controlled conver- explained, assuming that the increase in the poly-
sion limit.15 At temperatures higher than 807C merization rate with temperature rise in the pres-
the conversion appears to decrease, suggesting in ence of oxygen is faster than the increase in rates
turn, the occurrence of degradation/depolymer- of decelerating processes like degradation/depoly-
ization processes. On the other hand, the chain merization or chain transfer at low conversion de-
transfer reaction, i.e., the abstraction of mobile grees reached in air. The exothermic effects of oxi-
hydrogens from initial components or polymer by dation processes may contribute to a degree to the
the growing macroradical can increase the rate of observed heat flow. The fast increase in R pmax of
bimolecular termination and decrease in this way OEDA and PDA with temperature in air is proba-
the polymerization rate. Activation energy of bly associated with acceleration of initiation by
chaintransfer reaction is higher by about 2040 peroxides formed.7,20 At low initiation rates (as in
kJ/mol from activation energy of propagation, 19 the present work), this effect may significantly
so, its contribution increases with polymerization affect the temperature dependence of the poly-
temperature. This reaction is probably responsi- merization rate. However, at higher initiation
ble for the drop in the polymerization rate with rates (higher light intensity and/or initiator con-
temperature rise above 907C for EPA polymeriza- centration), the effect of oxygen will be less pro-
tion in Ar at the early polymerization stages nounced because the contribution of peroxides to
(R 3p , Fig. 6) due to the presence of readily ab- the initiation process will be reduced. Thus, under
u conditions of fast initiation the temperature de-
stractable hydrogens H{C(OH) . For formula- pendencies of polymerization parameters in air
v should resemble those in Ar.
tions based only on monomers or containing EPA The lack of the maximum on the plots R pmax
and monomers in the molar ratio 1 : 2.5, R 3p in- and R 3p vs. temperature for EPA polymerization
creases monotonically with temperature, indicat- in air may result in part from earlier increase in
ing that the possible degradation/depolymeriza- chaintransfer effects due to oxygen assistance
tion processes are slow at very low polymer con- in this reaction.2 The reason of the rapid drop of
centrations (and at low concentration of trapped R pmax , R 3p , and p f values for monomer / oligomer
and mobile radicals) and that the chaintransfer compositions above 807C in air is still uncer-
reaction for the oligomeric component of the tain.
formulation is of little importance. The increase
of EPA content in the formulation ( 1 : 1 ratio )
stops further increase of R 3p with temperature The Influence of the Heteroatom
above 807C. From the plots presented in Figures 27 it is
As the polymerization proceeds, the degrada- clearly seen that the presence of the heteroatom
tion/depolymerization and chaintransfer pro- in the ester group of the reactive diluent exerts a
cesses intensify, due to an increase in polymer deep influence on the polymerization kinetics. The
(and radical) concentration and resulting in- beneficial influence of the heteroatom is much
crease in concentration of tertiary hydrogen more pronounced in air atmosphere and is consid-
atoms in the polymer backbone. This is mani- erably stronger for the sulfide than for the ether
fested by the appearance of a plateau on the plots group.7,21 Obviously, the effect of the heteroatom
of R pmax vs. temperature and a declining tendency is the strongest in the polymerization of the mono-
of R pmax and p f at the highest temperatures (Figs. mers, but it is also kept in composition of the
2 and 4). monomers with EPA. The exemplary comparison
Somewhat different temperature dependencies of the reaction rate profiles for the monomers,
are observed for polymerization in air (Figs. 3, 5, EPA, and their mixtures in the 1 : 1 molar ratio
and 7). The values of p f , R pmax , and R 3p for the at 807C in air is given in Figure 9. The results of
monomers and oligomer increase monotonically TEDA, OEDA, and PDA polymerization are con-
with temperature, whereas p f , R pmax and R 3p val- sisted with those obtained previously.7
ues of the mixtures of monomers and oligomer The differences in the polymerization kinetics
pass through a plateau at about 50807C. of the monomers studied result from the ability

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672 ANDRZEJEWSKA AND ANDRZEJEWSKI

attached to sulfur atom are considerably higher


than those for hydrogens in a CH2 group attached
to oxygen atom and higher than for tertiary hy-
drogens 19 ). The importance of this reaction in the
polymerization of diacrylates was shown for the
formulations containing sulfide additives of vari-
ous structures.23 Thus, the TEDA-based formula-
tions are least sensitive to oxygen inhibition as
well as give the best results when polymerized
in Ar. These properties, together with improved
thermooxidative stability and reduced solvent
and moisture absorption 6,7 of the resulting poly-
mer, makes TEDA useful for potential applica-
tions as the reactive diluent in production of pro-
Figure 9. Reaction rate profiles of the monomers, tective coatings.
EPA, and their mixtures in the 1 : 1 molar ratio at 807C
in air.

CONCLUSIONS
of the CH2 group attached to heteroatom to donate
hydrogen.7 In air, this reaction leads to significant The photoinitiated polymerization of acrylic res-
reduction of oxygen inhibition due to acceleration ins based on the epoxyacrylate oligomer and dia-
of oxygen consumption in the peroxidation pro- crylate monomers is characterized by the syner-
cess: gistic effect occurring in a wide temperature
range. Synergism is observed for the maximum
polymerization rate both in air and in Ar and for
ROO 1CHX
ROOH 1CHX (1) final conversions in air. The strongest effect oc-

CHX 1 O CHX (2) curs for the equimolar oligomer-to-monomer ratio.
OO
Such composition gives the optimum effect of in-
creasing the polymerization rate at early and me-
dium polymerization stages and low and medium
where X 5 S or O.
reaction temperatures as well as reduction of oxy-
gen diffusion in air. In Ar, the final conversions
This is the main reason of faster polymerization increase with the decrease in viscosity of a formu-
rates and higher conversions of heteroatom-con- lation. The presence of a heteroatom (S or O) in
taining monomers and their compositions in air. the ester group of the reactive diluent is beneficial
Another possible reaction, hydrogen abstrac- for the polymerization course, especially in air at-
tion by growing macroradical both from the poly- mosphere. The best results were obtained for the
mer and monomer [reaction (3)], leads to en- sulfur-containing monomer.
hanced network crosslink density due to grafting
and introduces some mobility to radical sites The authors thank Dr. W. Charmas for synthesis of the
attached to the network. oligomer. This work was supported by grant of the Poznan
University of Technology number DS-32/282/97.
M 1 CHX
MH 1 CHX (3)

where ; M is macroradical. REFERENCES AND NOTES

1. S. P. Pappas, Ed., Radiation Curing Science and


This reaction affects the kinetics especially in
Technology, Plenum Press, New York, 1992.
Ar and may be responsible in part for larger con-
2. J. G. Kloosterboer, Adv. Polym. Sci., 84, 1 (1988).
versions of TEDA- and OEDA-based formula- 3. Ullmanns Encyclopedia of Industrial Chemistry,
tions. A14, VCH Verlagsgesellschaft mbH, D-6940 Wein-
The hydrogen abstraction occurs easier in the heim, 1989, p. 171.
case of {CH2{S{ group 19,22 (the chaintrans- 4. K. S. Anseth, S. M. Newman, and C. N. Bowman,
fer constants for hydrogens in a CH2 group Adv. Polym. Sci., 122, 176 (1995).

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PHOTOCURABLE ACRYLIC RESINS 673

5. H. R. Ragin, in ref. 1, ch. 7. 15. W. D. Cook, Polymer, 33, 2152 (1992).


6. A. Voelkel, E. Andrzejewska, R. Maga, and M. An- 16. W. D. Cook, J. Polym. Sci., Part A: Polym. Chem.,
drzejewski, Polymer, 37, 455 (1996). 31, 1053 (1993).
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Sci., Part A: Polym. Chem., 31, 2365 (1993). 18. E. Andrzejewska, Polymer, 37, 1047 (1996).
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12. J. F. Rabek, Mechanism of Photophysical Processes 6-31G* level) the energy needed to break the C{H
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