Polyacrylate Latex Coating Binders Comprising Polypyrrole Component Prepared with “One-Pot” Synthesis

This work deals with the coating properties of synthetic latices comprising two kinds of polymers, specifically polyacrylate and polypyrrole, which were simultaneously formed by semi-continuous emulsion polymerization using a “one-pot” synthesis strategy. In this procedure, both the emulsion polymerization of acrylate monomers and the oxidative polymerization of pyrrole occurred concurrently in one reactor. Polyacrylate latices differing in polypyrrole loading were prepared by applying various dosages of pyrrole, specifically 0, 0.25, and 0.50, based on the fraction of acrylate monomers. The effect of the in situ incorporated polypyrrole component (having the nature of submicron composite polypyrrole-coated polyacrylate latex particles) on the physico-mechanical properties and chemical resistance of the resulting heterogeneous coating films was investigated. The interaction of incorporated polypyrrole and anti-corrosion pigments (see ZnS, Zn3(PO4)2, ZnFe2O4, MoS2, and ZnO) on the corrosion resistance of coatings was evaluated by using the electrochemical linear polarization technique. The polyacrylate latex prepared with the lowest polypyrrole loading (achieved by polymerizing 0.25 wt. % of pyrrole related to acrylic monomers) was found to be the optimum binder for waterborne anticorrosive coatings based on their properties and protective function. Their compatibility with the selected types of pigments was studied for these latex binders. In addition, their influence on the anti-corrosion efficiency of polyacrylate paint films was evaluated using the linear polarization electrochemical technique. For high corrosion resistance, the ZnS and MoS2 pigments, showing compatibility with polyacrylate latices containing the polypyrrole component, proved to be advantageous.