High solid content multisized emulsion copolymerization of styrene,butyl acrylate,and methacrylic acid

Polymer lattices with a multimodal particle size distribution (PSD) polymer latex were prepared by introducing additional surfactants during the semicontinuous emulsion polymerization of styrene, butyl acrylate, and methacrylic acid. The polymerization was investigated by following the variation of the particle size, the size distribution, the number of particles, the T_g of the different particle sizes, and the total conversion at different steps of the polymerization process. The results show that bimodal and trimodal PSD polymer lattices can be obtained by this method and that the secondary generation of particles is greatly influenced by the nature and the amount of additional surfactants, as well as the moment when they are introduced. When the amount of additional surfactants is increased, the diameters of both the small and large particles decrease and the number of particles in each of the populations increases. Earlier introduction of these surfactants favors the generation and the growth of the small particles and thereby leads to a reduction of the relative fraction of large particles in the final latex. On introduction of 7 wt % of additional surfactants, based on the total monomers, 100% of the monomers of the second-stage polymerization were consumed to form the small particles. This fraction decreases with a decreasing amount of the additional surfactants. These results were further demonstrated by measuring the T_g's of both the large and the small particles of two lattices, in which the T_g's of the copolymers produced in each of the stages were different. High solid content (>65%), low viscosity, and coagulum-free lattices have been obtained through secondary nucleation, and a minimum in viscosity was found when the weight fraction of the large particles was around 80%. © 1998 John Wiley & Sons, Inc. J Appl Polym Sci 70: 2667–2677, 1998