Latex Film Formation: The Process Of A Latex Film Formation

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3.4 Latex Film Formation

The process of transforming a stable dispersion of colloidal polymer particles into a continuous film is called “latex film formation”. It involves many steps that span from a dilute through to a concentrated dispersion, into a packed array of particles, and eventually into a continuous polymer film. From a modeling perspective, it is conventional to split the process into three sequential steps (drying, particle deformation, and diffusion) which each steps can overlap in time [37-40].

The film formation process, sketched in Figure 3.8, has a pronounced influence on the final film properties. When a stable dispersion (state 1) is deposited on a surface and subject to evaporation (stage 1), the particles consolidate …show more content…

The rate of evaporation has been determined as being the same as the rate of evaporation from water. The first stage is the longest of the three until the polymer has reached approximately 60-70% volume fraction or until the surface area of the liquid-air interface starts to decrease as a result of solid film formation. The second stage starts when the particles first come into irreversible contact. The rate of evaporation per unit area of open wet latex remains constant, but the overall rate of evaporation decreases greatly during this stage. Reducing of the rate of evaporation can lead to better quality films by allowing the particles more time to pack into an order structure.

The last stage starts with the initial formation of a continuous film. The remaining water leaves the film initially via any remaining interparticle channels and then by diffusion through the fused polymer skin, but the rate of evaporation eventually slows to approach that of diffusion alone.

The spatial distribution of particles in latex film is important in determining the evaporation rate as well as the resulting film microstructure. The observation is that inhomogeneities are observed both in the vertical and in the horizontal (in the film plane) …show more content…

Dry sintering is a common mechanism in other types of particulate materials, such as ceramics made from oxide powders. It was originally proposed by Dillon et al. [48], important experimental evidence is presented by Sperry et al. [49] who followed the cloudy-clear transition of a film by using a minimum film formation temperature bar. Their results prove that water is not relevant in the deformation around the cloudy-clear transition, at least for the acrylic films. They concluded that the film formation process can be separated into two independent steps. In the first, water evaporates completely and in the next, particles are deformed due to polymer-air interfacial tension and van der Waals

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