Preparation and properties of urethane/acrylate composite by emulsion polymerization technique

Aqueous polyurethane–acrylic hybrid emulsions were prepared by semibatch emulsion polymerization of a mixture of acrylic monomers (styrene, butyl acrylate and acrylic acid) in the presence of polyurethane dispersion. Equivalent physical blends were prepared by mixing acrylic emulsion and polyurethane dispersion. The weight ratio between acrylic and polyurethane components was varied to obtain enhanced performance properties and microphase structure of hybrid latexes. The synthesized emulsion hybrids and physical blends were characterized by fourier transform infrared spectroscopy, thermogravimetric analysis. The experimental results indicate better acrylic–polyurethane compatibility in hybrid emulsions than in physical blends, resulting in improved chemical and mechanical properties. The blend ratio 50:50% (w/w) exhibited synergistic effects between the two polymers and revealed remarkable improvement in various coating properties over other blend ratios and the individual resin components.