Synthesis of styrene–butadiene rubber latex via miniemulsion copolymerization

High-butadiene-level styrene–butadiene rubber latexes up to high solid-contents are synthesized using the miniemulsion process. It is shown that the miniemulsion polymerization approach offers an efficient heterophase route synthesizing styrene–butadiene copolymer latexes with flexible copolymer composition and narrow size distribution of the resulting latex particles. Secondary nucleation was successfully prevented by using a hydrophobic initiator. Due to the nanoreactor situation, even at high conversions, a low crosslinking degree and, therefore, low gel contents are obtained. The microstructure of the polymers obtained in miniemulsion is independent of the synthesis parameters, especially the temperature. The molecular weight can be easily adjusted by the application of transfer agents while the insoluble gel content is substantially reduced. An up-scaling of the procedure is easily possible.