The formation mechanism of poly(vinyl acetate)/poly(butyl acrylate) core/shell latex in two-stage seeded semi-continuous starved emulsion polymerization process

In this paper, the morphological evolution of latex particles on poly(vinyl acetate) (PVAc)/poly(butyl acrylate) (PBA) in two-stage seeded semi-continuous starved emulsion polymerization is studied, and the thermodynamic analysis and a mathematic model are derived to describe the interfacial free energy changes corresponding to various possible thermodynamically unstable morphologies during the polymerization process. The comparisons between the morphological evolution and the related thermodynamic analysis show that the morphological evolution of latex particles is oriented to the thermodynamic preferred morphology which is an inverted core/shell structure with PBA as core and PVAc as shell. Based on the comparisons, the possible morphological developmental pathway of PVAc/PBA core/shell latex is described. The possible morphological developmental pathway suggests that the observed multi-particle morphology in the polymerization process is due to restricted chain mobility related to high internal viscosity. The formation mechanism of PVAc/PBA core/shell latex, based on the experiments as well as the thermodynamic and dynamic analyses, is proposed, which signifies that PBA is first formed outside the PVAc seed and then migrate to the inside of the PVAc seed.