APE free surfactants for the emulsion polymerization of vinyl-acrylic emulsion polymer

The polymerization process used to synthesize vinyl-acrylic emulsions is complex, and the replacement of APE surfactants for EHS-friendly solutions increases the complexity. The higher polarity of the polymer due to the very hydrophilic vinyl-acetate monomer decreases surfactant adsorption and can also decrease the water resistance of the final coating. Therefore, surfactant choice is crucial in the development of stable formulations.    

To optimize the properties needed in the emulsion; grit formation, shear stability, ionic resistance and particle size, different anionic and nonionic surfactants were tested. The hydrophobe and hydrophilic tail of the surfactants were changed, and the polymerized emulsion properties were tested and compared both commercial and synthesized APE based emulsion polymers.

Finally, a 45% PVC paint was formulated with the vinyl-acrylic emulsion synthesized with the optimized APE-free surfactant ratio and commercially available emulsion resins. This led to an increased wet scrub resistance of 200% when compared against the APE-free surfactants and 230% increase when compared against the APE-free emulsion commercially available.