Journal of Applied Polymer Science, Vol.84, No.10, 1935-1948, 2002
High solids content emulsions. IV. Improved strategies for producing concentrated latices
A new means of producing high solids content latices with low viscosity is presented. The replacement of water-soluble initiators that decompose to give charged free radicals is shown to perturb the stability of highly concentrated latices. Their replacement by an oil-soluble initiator during particle growth, then by an activated, water-soluble system to remove residual monomer has been shown to help significantly reduce the number of stable particles generated by homogeneous nucleation. Latices with 73% (v/v) solids have been produced with a bimodal particle size distribution (PSD) consisting of 900 and 110 nm particles. The viscosity of these latices can be as low as 300 mPa s(-1) at 20 s(-1). Despite the presence of water-soluble monomers, excellent control over the evolution of the PSD allows one to obtain highly reproducible results. In addition, latices produced with the new initiator system have a much lower water uptake and their viscosity is much less sensitive to changes in pH than is the case for latices produced using standard emulsion polymerization techniques.