Comparison of properties of acrylic-polyurethane hybrid emulsions prepared by batch and semibatch processes with monomer emulsion feed

Aqueous acrylic-polyurethane hybrid emulsions were prepared by batch and semibatch polymerization of acrylic monomer mixtures (butyl acrylate, methyl methacrylate and acrylic acid) in the presence of polyurethane dispersion. The acrylic component was introduced in the monomer emulsion feed. The weight ratio between acrylic and polyurethane components was varied to obtain different emulsion properties, microphase structure and mechanical film properties. Scanning electron microscopy, average particle size and molecular weight measurements were performed to characterize the latex systems. Mechanical properties were examined by measuring Koenig hardnesses of dried films. The average particle size increased with the acrylic/polyurethane ratio. Particles of larger than average size and, to some extent, higher than average molecular weights by batch process were formed. Koenig hardnesses decreased with increasing acrylic/polyurethane ratio. Properties of emulsions synthesized by semibatch processes were compared with the results reported for a different polyurethane dispersion. (C) 2003 Society of Chemical Industry.