| Abstract: | Latex interpenetrating and semi-interpenetrating polymer networks (LIPNs and semi-LIPNs) combine the morphological characteristics of bulk-polymerized IPNs with the characteristics of polymers produced by emulsion polymerization; there are IPN structures within the latex particles. These LIPNs can be injection-molded using standard thermoplastic methods and machinery. A dual thermoset—thermoplastic nature characterizing the LIPN manifests itself in the mechanical and rheological behavior reflecting unique morphologies. These morphologies result from a sequential two-stage latex (TSL) polymerization and include core—shell, domain, interpenetrating polymer networks and various other combinations. Elastomeric TSL with crosslinked polyacrylates (xPA) as the first stage and crosslinked polystyrene (xPS) as the second, each stage lightly crosslinked, yield IPN-nano-domain structural particles. Upon molding, the particles become interconnected by joint PS nanodomains, introducing a particle—particle strength-forming mechanism. The intraparticle glassy PS nanodomains reinforce the soft elastomeric particles enhancing their modulus. Glassy “all-styrene” semi-LIPNs made of PS and xPS show improved mechanical performance compared to PS, while exhibiting good transparency. Volumetric crazing in these PS/xPS materials develops in tension-improving elongation and strength. The presence of xPS particles, denser and thus stiffer than the PS matrix, renders a higher modulus. Essentially xPS highly filled blends are achieved along with significant particle—matrix interactions. The ability to generate a controlled plethora of morphologies offers a wealth of potential applications, from reinforced elastomers to high impact plastics. Poly(acrylonitrile—butadiene—styrene), a semi-LIPN, is a commodity plastic, clearly demonstrating the utilization potential of the TSL procedure for generating very fine multiphase materials of scientific and technological merits. |
