The concentrated emulsion approach to toughened polymer composites: A review

Abstract A series of tough polymers were prepared by combining flexible with rigid chains, using the method of concentrated emulsion polymerization. The tough materials obtained can be classified into four types: [a] those prepared via the polymerization of a monomer containing a dissolved elastomer, starting from its concentrated emulsion in water; [b] those prepared via heterogeneous (interfacial) crosslinking of two partially polymerized concentrated emulsion in water containing incipient latexes; [c] those prepared as semi‐interpenetrating or AB network latexes, starting from a concentrated emulsion in water and [d] those prepared by mixing two partially polymerized concentrated emulsions and completing the polymerization. A concentrated emulsion differs from the conventional emulsion in that the volume fraction of the dispersed phase is higher than that of the most compact arrangement of monosize spheres (0.74) and can be as high as 0.99. The cells of a highly concentrated emulsion are no longer spherical, but polyhedral in shape, compactly packed and separated by thin films of continuous phase. As a result of such structure, a high polymerization rate and a high molecular weight can be achieved, the size (in the colloidal range) of the flexible phase can be controlled and the latter phase can be uniformly dispersed in the rigid one. Consequently, the concentrated emulsion method constitutes a suitable pathway to toughened composites. Owing to the compact packing of cells, the concentrated emulsion polymerization method is particularly suitable for cases in which reactions occur at the cell interface. For the materials of type [d], these reactions generate quasi‐block copolymers, which compatibilize (via “auto‐compatibilization”) the components of blends.