Transformation of waterborne hybrid polymer particles into films: Morphology development and modelling

Films cast from multiphase polymer particles have the potential to combine the properties of their components synergistically. The properties of the film depend on the hybrid polymer architecture and the film morphology. However, how the polymer microstructure and particle morphology are transformed during film formation to determine the film morphology is not well understood. Here, using waterborne alkyd-acrylic nanocomposite particles in a case study, it was found that phase migration leading to the formation of aggregates occurred during film formation. A coarse-grained Monte Carlo model was developed to account for the effects of polymer microstructure and particle morphology on the morphology of the film. The model was validated by comparing its predictions with the observed effects, and then used to explore combinations of polymer microstructure and particle morphology not attainable with the system used as a case study. Significantly, the morphology of the particles was found to have a greater influence than the compatibility of the phases in determining the film structure.