Achieving optimum balance between mechanical properties and gloss of acrylonitrile–styrene–acrylate resin through control of rubber particle size distribution

Abstract Preparation of acrylonitrile–styrene–acrylate (ASA) with high gloss and superior impact properties is still challenging. Here, we developed a new strategy for the preparation of ASA resins by a selective redox initiation method based on a semi‐continuous emulsion polymerization technique. A series of ASA core‐shell impact modifiers were firstly obtained by grafting styrene (St) and acrylonitrile (AN) onto poly( n ‐butyl acrylate) (PBA) seeded latexes of different sizes. The ASA core‐shell impact modifier was then used to toughen the styrene–acrylonitrile copolymer (SAN). The synergistic effects between the single particle size of the rubber phase and different particle sizes were systematically investigated, and the mechanical properties of SAN‐toughened resins at various particle sizes of the rubber phase were analyzed. The results revealed that toughened SAN with small particle sizes possessed better gloss, and the impact strength of the doped small‐particle toughened SAN was much higher than that of the single particle size toughened SAN. The ASA graft powders synthesized from large particle PBA (particle size 316 nm) and small particle PBA (particle size 99 nm), respectively, were mixed at a 50/50 ratio and blended with SAN resin, a gloss level reaching 95, and an impact performance of 275 J/m values almost twice those of a single particle size toughened SAN. Highlights Acrylonitrile–styrene–acrylate resins with an impact strength of 275 J/m and gloss of 95 were prepared. The balance between mechanical properties and gloss of acrylonitrile–styrene–acrylate resin was obtained. Polymerization was initiated at low temperature.