DOWANOL DPM POOR WETTING c5
DOWANOL DPM POOR WETTING c5
DOWANOL DPM POOR WETTING c5
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In the chapters 3 and 4 it has been shown that transparent films can be
formed from PBMA latexes encapsulated with a polypyrrole shell. The rate
of film formation strongly depends on the thickness of the polypyrrole shell
and on the temperature at which the film is formed. Since film formation at
high temperatures has a number of disadvantages, such as loss of
conductivity and limitation of substrate composition and size, the possibility
to form transparent films from a 1 wt% PPy-encapsulated PBMA latex at
room temperature has been investigated in this chapter.
Three different routes to form such films have been investigated. It has been
found that it is possible to obtain transparent films from blends of
encapsulated latexes and film-forming latexes, but the quality of the films is
rather low. The homogeneity of the films is not very good, resulting in
“sandy-like” structures in the films. This is attributed to colloidal instability
of the latex.
A second method to form films at room temperature is by using low-Tg
acrylic latex particles or PBMA latex particles with a low-Tg shell as the
core particles. Depending on the Tg of the polymer and the thickness of the
acrylic shell it is possible to form films based on these latexes, but these
films proved to be electrically insulating or inhomogeneous.
A third method is to employ so-called coalescing aids. It has been found that
it is indeed possible to obtain homogeneous transparent films from 1 wt%
PPy-encapsulated PBMA latexes with a proper choice of the coalescing aid.
The best results were obtained with Dowanol EPH, which is an ethylene
glycol phenyl ether. Films formed with this coalescing aid can have a
transparency of well over 90%. The film transparency is found to depend on
the concentration of coalescing aid, the film thickness, and on the relative
humidity at which the film is formed.
Chapter 5
5.1 Introduction
In the previous chapters it has been shown that conducting latex particles
with an acrylic core and an ICP shell can be prepared and that transparent
films can be obtained from such encapsulated latexes by heating. It was
shown that the ICP shell forms a strong barrier against film formation and
high temperatures and/or long annealing times are necessary to obtain
transparent and mechanically strong films. Such a heat treatment has a
number of disadvantages. It limits the practical applicability of the
conducting film, because severe prerequisites are set for the substrate on
which the coating is applied. The size and shape of the sample on which the
film is applied are limited because it has to be heated in an oven. Finally, it
is well known that ICPs often suffer from loss of conductivity with time,
especially at elevated temperatures [1]. Although polypyrrole is one of the
most stable ICPs with respect to its conductivity, it is advisable to prevent
elevated temperatures as much as possible.
In recent years more and more research effort is directed to the combination
of different polymers in order to prepare materials which combine the
desirable properties of the individual components and have a good overall
performance. One of these areas is the preparation of polymeric films from
blends of latexes [2, 3]. It has been shown that when a film-forming latex is
blended with a non-film-forming latex, a transparent film is formed if the
non-film-forming particles are uniformly distributed in the polymer matrix
generated from the deformed soft particles. However, if the hard latex
particles form clusters, the resulting film is turbid [2]. Various factors, such
as the size ratio between the two types of particles, the presence of
surfactants, and annealing of the films after drying, influence the uniformity
of the particle packing that is required for transparent films. If the size of the
latex particles is comparable, transparent films are formed if the soft particle
volume fraction exceeds ~0.5 [4]. At lower volume fractions voids are still
present in the film. These voids can scatter light and reduce the film
transparency. Which of the two polymers in the latex blend forms the
continuous matrix does not only depend on the volume ratio between both
latexes, but also on the ratio of their particle sizes [5]. When the differences
in particle size are significant (dhard/dsoft = 4–10) a continuous matrix of the
soft particles can be formed with only 30 vol% of the soft particles if the
packing of the particles is good [5, 6, 7].
To the best of our knowledge, there is only one report of the preparation of
latex blend films with ICPs. Cooper et al. [8] have prepared blends of a
PMMA/PBA latex with preformed PANI and PPy particles. The diameter of
the acrylic latex was about 160 nm and the polypyrrole particles were rather
polydisperse with most particle diameters in the range 100–150 nm. From
these water-based systems, films could be prepared with a conductivity of
about 10-2 S/cm with only about 5 wt% PANI or about 20 wt% PPy. The
difference in the percolation threshold is attributed to the difference in shape
of the ICP particles; the PANI particles are needle-shaped and the PPy
particles have a more globular appearance. Cooper et al. reported that the
films essentially retain the mechanically properties of PMMA/PBA films up
to ICP particle concentrations of ~20 wt%. At higher concentrations the
films become brittle and easily torn [Error! Bookmark not defined.].
When we tried to prepare blend films based upon ICP-encapsulated latexes
and film-forming latexes, various difficulties were encountered. The main
problem is the colloidal stability of both latexes in the mixture and therefore
Chapter 5
In the third stage of the film formation process, the PBMA core keeps its
spherical structure. If the thickness of the low-Tg shell is high enough and
the Tg of this polymer is low enough, the soft acrylic shell will deform and
fill the voids between the latex particles. In our case the shell thickness and
the Tg of the soft acrylic shell are even more important, since the
encapsulation by polypyrrole gives an extra resistance against particle
deformation, as can be seen in the atomic force microscopy images shown
in Figure 5.2.
The images in Figure 5.2 were taken on thick latex films that were dried at
room temperature. In the left-hand figure, the particles are stacked nicely in
Chapter 5
a lattice and the boundaries between the individual particles are clearly
visible. This is as expected, since the particles were dried at room
temperature, so below the Tg of the latex polymer. In the picture in the
middle, the size of the spherical particles is the same as in the left-hand
figure, but they appear separated. This is due to the film formation of the
low-Tg shell polymer that was polymerized around the PBMA core particles.
The appearance of this sample is transparent, whereas the dried PBMA latex
is white due to the scattering of light by the voids in the sample.
Polymerization of a polypyrrole shell of about 1 nm around the latex
particles with the low-Tg shell hinders the film formation of the particles, as
can be seen in the right-hand figure. Here the boundaries are clearly visible
again. Since these samples are rather thick, the appearance of the PPy-
encapsulated film was very dark. That film formation had indeed occurred
in this case could be concluded from the mechanical strength of the film.
In general, core–shell particles with a low-Tg shell are used in order to get a
desired combination of properties, i.e. a good combination of the rate of film
formation and the hardness of the resulting film. In this study, such core–
shell particles are used since it offers the possibility to use the same PBMA
core latex and polymerize low-Tg shells with different properties
(composition and nature of the monomer) around this core latex. This
enables the comparison of the influence of the different shells independent
of factors like the exact size and composition of the core latex.
It was found that transparent latex films can be formed from PPy-
encapsulated latex particles with a low-Tg inner shell and a diameter of
about 800 nm if the Tg of the shell-polymer is below –15 °C and the
thickness of the shell is at least 50 nm. The colloidal stability of these
latexes, however, is found to be worse than that of encapsulated latexes with
a pure PBMA core. The reason for this lower colloidal stability is not
understood. A possible explanation could be a lower binding efficiency
between the HEC thickener and the acrylic latex during the in-situ
polymerization of the pyrrole, but the reason for such a lower binding
energy is not clear. The lower colloidal stability of the latex, however, has a
negative influence on the quality of the films. Via incorporation of acrylic
acid groups in the shell it is possible to prepare latexes that are colloidally
stable even during the in-situ polymerization of pyrrole. However, as has
already been said in chapter 2, such latexes proved to be non-conducting
and were therefore not used further in this study. Since films with much
better optical properties could be obtained at room temperature using other
methods, the colloidal stabilization of PPy-encapsulated latexes with a low-
Latex film formation at room temperature
Tg inner shell has not been investigated in more detail. However, since this
method has proven to be applicable and since it really enables the formation
of transparent films at room temperature without extra additives, it deserves
further investigation.
It was observed that the wetting of the glass slide by the different latexes is
very different, ranging from very good for the sample with Dowanol EPH to
rather poor for the sample with Dowanol EB and Dowanol DPM. A poor
wetting results in inhomogeneous drying of the film and thus in an
inhomogeneous film. In the paint industry, such drying effects are often
solved by a modification of the paint viscosity via rheology modifiers or
thickeners. A second mode of action of such a thickener is that it can change
the properties of the aqueous phase and make it better wetting the substrate.
Therefore, latex films have been prepared with a hydrophobic polyurethane
thickener that is often used in latex systems, SER AD FX 1100. The amount
of thickener used is about 5 wt% relative to the total (wet) latex. The
amount of coalescing aid relative to the solid latex polymer is 20 wt%. The
thickness of the wet films is approximately 15 µm. The final transparencies
of the thus prepared latex films are plotted in Figure 5.3.
Latex film formation at room temperature
100
80
Transparency (%)
60
40
20
0
Dowanol EB
Dowanol DPM
Dowanol PnB
Texanol
Vestinol AH
Dowanol EPH
Figure 5.3 Transparencies of films prepared with different coalescing
aids from a 1 wt% PPy-encapsulated PBMA latex at room temperature with
5 wt% SER AD FX 1100; Relative Humidity (RH) = 94%; wet film
thickness = 15 µm; [coalescing aid] = 20 wt%; solid content = 14.6%.
As can be seen from Figure 5.3, large differences in film transparency are
found with the different coalescing aids and, more important, it is possible
to obtain transparent films from the encapsulated latexes at room
temperature. In Chapter 6 is shown that these transparent films can possess a
resistance of less than 100 kO/?, so it is possible to prepare transparent,
antistatic films at room temperature.
The performance of Dowanol EPH as a coalescing aid is superior in
comparison with the other coalescing aids. As has been said in the
beginning of this paragraph, the mode of action of coalescing aids is very
complicated and therefore it is not possible to relate the coalescing strength
directly to a certain property. In this case, however, a possible explanation
for the superior performance of Dowanol EPH could be its chemical
structure in combination with its partition in the water phase and the latex
particle. As has been shown in the previous chapters, the polypyrrole shell
forms the main resistance against deformation of the encapsulated latex
particles. One of the characteristics of polypyrrole is its conjugated ring-
structure; a structure that is also present in the two coalescing aids that give
Chapter 5
the best results, Dowanol EPH and Vestinol AH. Therefore, some affinity
between the polypyrrole and these coalescing aids can be expected. The
difference in performance of Vestinol AH and Dowanol EPH is possibly
due to the difference of the partition of the coalescing aid inside the latex
particles. The water solubility of Dowanol EPH is much larger than that of
Vestinol AH. Upon evaporation of the water, the coalescing aid that was
present in the water phase will be forced into the latex particles, because its
evaporation rate is lower than that of water. Therefore it can be expected
that immediately after the evaporation of the water, in the case of Dowanol
EPH more coalescing aid will be present at the outside of the particle than in
the case of Vestinol AH. The main resistance against deformation, the
polypyrrole shell, is located only at the surface of the latex particle. Since
more Dowanol EPH will be located near this shell, this might be an
explanation for the better performance of this coalescing aid.
Since the samples with Dowanol EPH as the coalescing aid give the best
results, this coalescent is selected for further experiments.
The viscosity of the aqueous latexes can be adjusted not only by the addition
of thickeners, but also by the concentration of the latex in the water.
Therefore, part of the water phase is evaporated prior to the addition of the
coalescing aid, until the solid content of the latex is about 28 %. Such a
solid content proved to be high enough for the preparation of homogeneous
films from the 1 wt% PPy-encapsulated latexes with Dowanol EPH as the
coalescing aid. The concentration process does not have a negative
influence on the colloidal stability of the latex, neither immediately, nor in
the long term. This concentrated encapsulated latex, without any additional
thickener, is used for further experiments.
So far, the concentration of the coalescing aids has been kept constant at
20 wt% relative to the solid polymer. Since coalescing aids are organic
liquids, they evaporate from the film. The use of so-called volatile organic
compounds in paints is reduced as much as possible since such compounds
are suspected of causing the Organic Psycho Syndrome (OPS) and the
greenhouse effect. Therefore, the influence of the concentration of Dowanol
EPH on the final film transparency is investigated.
Latex film formation at room temperature
100
Transparency (%) 80
60
40
20
0
0 5 10 15 20 25
wt% Dowanol EPH
limits the time that the particles can move in the liquid and may therefore
result in a poorer stacking of the particles in the film and thus in an increase
in number and size of the voids.
The influence of the rate of water evaporation on the film transparency was
investigated by forming the film at different relative humidity (RH). At a
higher RH, the driving force for water evaporation is lower, leading to an
increase in the time interval that the particles can move in the water phase.
This decrease in evaporation rate indeed has a positive influence on the film
transparency, as can be seen in Figure 5.5.
100
90
Transparency (%)
80
70
60
50
40 60 80 100
Relative humidity (%)
larger voids will be present in the film formed at low RH. Second, water
evaporation is an endothermic process, thus the evaporation of water will
decrease the actual temperature of the latex during coalescence. Hence, the
shear modulus of a latex drying at low RH will be higher than the shear
modulus of the same latex drying at a higher RH. The deformation is
facilitated in the latter case, resulting in a film with smaller voids and thus a
higher transparency [14].
5.5 Conclusions
The best results have been obtained with Dowanol EPH, which is an
ethylene glycol phenyl ether. The superior coalescing power of this
coalescing aid might be attributed to the presence of a conjugated ring in its
structure in combination with an intermediate partitioning between the water
and polymer phase. It has been shown that another coalescent, with a
conjugated ring but with a much lower water solubility, is only slightly less
effective, while other coalescents, without the conjugated ring, are much
less effective.
the film in order to get the optimum lattice-like particle stacking and it also
reduces the actual temperature of the film. This results in an increase of the
size of the voids in the film and thus in a reduction of the film transparency.
5.6 Experimental
Latex synthesis
The core PBMA latex was synthesized in an emulsifier-free batch synthesis
according to the procedure described in chapter 3. The diameter of the latex
that was used throughout this chapter was determined using a Brookhaven
Instruments BI-DCP Particle Size Analyzer. The diameter of the particles
was about 800 nm unless indicated otherwise.
Two different routes have been employed for the formation of the latex
particles with a low-Tg inner shell. In the first method, first a PBMA latex is
synthesized according to the emulsifier-free batch method and this latex is
subsequently dialyzed in order to remove excess initiator and salt. Next,
oxygen is removed from the latex again by bubbling N2 through the mixture
followed by the formation of the low-Tg shell via a semi-continuous
polymerization of the shell polymer. In the second method, the core latex
was polymerized according to the same procedure. The shell, however, was
polymerized directly on this core in a semi-continuous polymerization, so
no intermediate dialysis was performed. In the latter procedure, “living”
radicals can be present on the latex surface and therefore the acrylic shell
chains may be chemically linked to the core. An advantage of the first
method, however, is a better control of the monomer-to-oxidant ratio in the
shell polymerization. Furthermore, if one wants to compare the influence of
different shell compositions, it is possible to start with exactly the same core
latex thus ruling out the influence of this core on differences in, for
example, film formation. No relation between the mode of synthesis of these
latexes and their film formation behavior after encapsulation has been
observed.
Low-Tg latex particles that were used in blends were synthesized according
to the same procedure as the PBMA core particles. The size of the latex
particles was controlled by the monomer-to-oxidant ratio.
The polypyrrole encapsulation protocol has been kept constant throughout
the experiments described in this chapter. This protocol has been given in
chapter 3.
Latex film formation at room temperature
Laser light
Water out
Sample
RH control
Water in
Photodiode
signal
to computer
Figure 5.6 The film-drying chamber and the optical detection system.
Chapter 5
Additives
The coalescing aids Dowanol EB, Dowanol DPM, Dowanol PnB, and
Dowanol EPH were kindly donated by Dow. Texanol was kindly donated
by Eastman Chemical Company, and Vestinol AH was kindly donated by
Hüls AG. All coalescing aids were used as received. The latexes with
coalescent were allowed to stabilize and reach equilibrium by stirring them
gently for at least one week.
The thickener SER AD FX 1100 was kindly donated by Servo Chemicals.
The thickener was used as received and added to the latex as a 3.85 wt%
solution in water. The latexes with thickener were allowed to stabilize and
reach equilibrium by stirring them gently overnight.
5.7 References
15 The physical properties of the coalescing aids are taken from the
suppliers materials data sheets
Chapter 5