| Film formation from hard/soft (i.e., high Tg/low Tg) latex blends consisting of hard polystyrene (PS) and soft poly(n-butyl methacrylate-co-n-butyl acrylate) [P(BMA/BA)] latex particles were studied with an emphasis on the influence of the carboxyl groups present on the latex particles. A theoretical model was developed to calculate the optimal surfactant and monomer feed rates for a semicontinuous polymerization process to synthesize monodisperse carboxylated latex particles and independently control the particle size and degree of carboxylation. An important finding obtained from the drying studies is that the drying rate from the edge zone is much faster than the rate obtained from the latex pool. It was also found that the presence of carboxyl groups on the latex particles retarded the drying rate. Utilizing PS particles with a low density of carboxyl groups present on the particle surfaces (e.g., 10% surface coverage) resulted in an even distribution of these particles in the soft copolymer matrix, and thus, good film gloss was achieved. However, the use of hard particles with a high density of carboxyl groups present (e.g., 65% coverage) resulted in a less even distribution of PS particles and poor gloss. A cluster model and a hydrogen bonding mechanism were proposed to explain these phenomena. The presence of the carboxyl groups on the PS particles significantly enhanced the Young's modulus and the yield strength, but did not influence the ultimate mechanical properties. A quantitative model was proposed to predict the Young's modus of the latex blend films as a function of the carboxyl group coverage on the hard particles. There was a good fit between model and the experimental data.;The stability of the precipitated calcium carbonate (PCC) particles in the P(BMA/BA) latexes was determined by the charge on pigment surface which, in turn, was influenced by the presence of sodium polyacrylate stabilizer. It was found that the wetting ability of the soft copolymer on the PCC particles was improved in the presence of the carboxyl groups on the binder particles via an acid-base interaction, which increased the uniformity of the PCC particle distribution within the binder matrix. |
