15

Preparation of solutions,
dispersions and emulsions for
latex compounding

15.1 GENERAL CONSIDERATIONS

With a few exceptions, compounding ingredients are added to aqueous Jaul:e:.
as aqueous solutions if they are water-soluble solids or liquids, as dispersions
if they are water-insoluble solids, and as emulsions if they are water-insoluble
liquids. Notable exceptions to this general rule include the direct addition
of dry fillers to certain latex compounds for the manufacture of latex foam
rubber, and the direct addition of ester-type plasticizers to vinyl acetate
polymer and copolymer latices.
General principles concerning aqueous solutions, dispersions and emulsions
for addition to aqueous latices which have found wide acceptance include
the following:

1. The particle size of dispersions, and the droplet size of emulsions, should,
as far as possible, be comparable to the particle size of the latex to which
they are to be added. The primary consideration which underlies this
principle is the assumption that the particles of polymer and of the
compounding ingredient should be capable of mixing intimately when a
solid phase separates from the compounded latex, either by coacervation
or by evaporation of the dispersion medium. A secondary consideration
is that sedimentation of dispersions of compounding ingredients during
storage is likely to be minimized if the particle size is reduced to that of
a typical latex. It is generally accepted that the particles in dispersions of
solid compounding ingredients should certainly have diameters less than
ca. 51lm, and should preferably have diameters in the range ca. 1-2Ilm.
However, this broad principle has to be interpreted to some extent in the
light of the application for which the latex compound is required. Thus,

D. C. Blackley, Polymer Latices

© Chapman & Hall 1997
2 Preparation of solutions, dispersions and emulsions

for instance, coarser particles of compounding ingredients can be tolerated

in latex compounds for the manufacture of latex foam rubber than in
those for the manufacture of dipped products or rubber thread.
2. The colloid stability of dispersions and emulsions should be comparable
to that of the latex to which they are to be added. Furthermore, it is
desirable that the stabilizing systems should be similar; if they are not,
then untoward colloidal interactions may occur with consequent colloidal
destabilization. In extreme cases, such interactions can lead to the mutual
colloidal destabilization of the latex and the added dispersions. Less drastic
interactions may be manifest as marked increases in viscosity and reduced
tolerance to chemical and mechanical destabilizative influences. As far as
solutions are concerned, the question of their colloid stability does not,
of course, arise. However, it is nevertheless important to ensure that there
is colloidal compatibility between a solution and the latex to which it is
to be added, because (see section 5.2 of Chapter 5 (Volume 1)) dissolved
substances can adversely affect the colloid stability oflatices by modifying
the nature of any electrical double layer at the particle surface, and also
that of any layer of adsorbed lyophilic macromolecular substances which
confer steric stabilization upon the latex.
3. As far as possible, the pH of solutions, dispersions and emulsions should
be similar to that of the latex to which they are to be added, thereby
minimizing disturbance of prevailing latex acid-base equilibria by the
addition of the compounding ingredients.
4. For a similar reason, it is desirable that the ionic strength of the aqueous
phase of the dispersion should be similar to that of the latex aqueous
phase. It is obvious that the types of electrolytes which give rise to the
ionic strengths in the respective aqueous phases should not be such that
untoward interactions occur either with each other or with the system
which confers colloid stability upon the other hydrophobic colloid.

Gorton and Pendle [lJ have reported the effect of the particle size of
dispersions of water-insoluble latex compounding upon the performance of
those ingredients in their intended functions in compounds based upon
ammonia-preserved natural rubber latex. The rather surprising overall
conclusion reached from this work is that, over the range of particle sizes
investigated, the particle size of dispersions of sulphur and vulcanization
accelerators has no significant effect upon the progress of the vulcanization
of latex deposits at temperatures in the range 100- 120°C, or upon the progress
of latex prevulcanization at 60°C. Likewise, little effect upon vulcanizate
physical properties was observed. Provided that sufficient antioxidant was
present in the latex compound, antioxidant particle size appeared to have
little effect upon deterioration during heat-ageing at 70°C in air. Typical
results reported by Gorton and Pendle are shown in Table 13.6 of Chapter
13 (Volume 2) and in Table 15.1 of this chapter. Table 15.1 shows the effect