Toughening of unsaturated polyester resins with core-shell rubbers

The effects of core-shell rubbers (CSRs) as tougheners on the fracture properties of unsaturated polyester (UP) resins during curing at 110 degrees C are investigated. CSRs were synthesized by two-stage soapless emulsion polymerizations; the soft core was made from rubbery poly(n-butyl acrylate), whereas the hard shell was made from methyl methacrylate, ethylene glycol dimethacrylate, and various concentrations of glycidyl methacrylate. Depending on the content of glycidyl methacrylate in the CSR shell and the amount of CSR added to the UP, the fracture properties of the CSR-toughened UP resins varied. The experimental results are explained by an integrated approach of measurements of the static phase characteristics of a styrene/UP/CSR system, the reaction kinetics, the cured sample morphology, the glass-transition temperatures, and the fracture toughness with differential scanning calorimetry, scanning electron microscopy, transmission electron microscopy, and dynamic mechanical analysis. Finally, the toughening mechanism for the CSR-toughened UP resins is also explored. (C) 2007 Wiley Periodicals, Inc.