In previous articles we have discussed emulsification of alkyd resins. We will continue with the focus on resins and discuss acrylic emulsion polymerization, in particular, surfactant design and how it affects the polymerization of a vinyl-acrylic emulsion. I would like to thank Bruno Dario of Indorama Ventures for being my coauthor on this series of articles, and Kip Sharp, Juliane Santos, and Fabricio Pereira of Indorama Ventures for their help. In this month’s article, I will introduce some of the materials and methods used. In the future, we will dive deeper into the characterization of the emulsions including particle size, filterable solids, electrolytical stability, and more.
The emulsion polymerization process to generate vinyl-acrylic latexes can be complex, and the replacement of alkylphenol-ethoxylate (APE)-based surfactants for environmental, health, and safety (EHS)-friendly solutions can be challenging. The higher polarity of the polymer decreases surfactant adsorption, and can also decrease the water resistance of the final coating; hence, surfactant choice is crucial in the development of resilient formulations.