Synthesis of a novel hybrid polymer emulsion and its performance in water-based paints

Purpose The purpose of this study is development of a novel hybrid polymer emulsion through graft copolymerization onto hyperbranched alkyd using monomers like vinyl acetate (VAM) and vinyl ester of versatic acid 10 (VeoVa 10) combination followed by emulsification of modified alkyd in water and use of such hybrid emulsion in paint formulation to improve the performance of coating film against conventional acrylic emulsion paint. Design/methodology/approach A hyperbranched alkyd was synthesized by condensation polymerization of vegetable fatty acid, polyol and polybasic acid followed by grafting of different combination of monomers to form hybrid resin system which on further emulsification form hybrid polymer emulsion. The performance of developed hybrid emulsion was evaluated by making paint and compared against traditional acrylic emulsion polymer as well as different grafted alkyd emulsion systems. Findings The performance of one of the prototypes alkyds grafted with VAM and VeoVa 10 monomer resulted in unique paint film properties like excellent gloss, gloss retention, hydrophobicity, resistance to salt spray, humidity and UV resistance. Research limitations/implications In the present study, soya fatty acid, different polyols, di basic acid, di methylol propionic acid as chain extender have been used to prepare hyperbranched alkyd and monomers like VAM, VeoVa 10 as well as different acrylic monomers used for graft copolymerization onto hyperbranched alkyd and emulsification of such hybrid resin system was carried out by using nonionic emulsifier. Practical implications The limitations of conventional acrylic emulsion paint with respect to inferior gloss, hydrophobicity, resistance to salt spray and humidity are improved by using such hybrid resin-based emulsion system. Originality/value VAM and VeoVa10 grafted hyperbranched alkyd-based hybrid emulsion have potential for use as binder for ecofriendly water-based coating for metal primer as well as topcoat in view of its’ superior performance with respect to hydrophobicity, resistance to salt spray, humidity and UV resistance.