Polymer-grafted Cellulose Nanocrystals and their Incorporation into Latex-based Pressure Sensitive Adhesives

Abstract

This thesis investigates the effect of reaction media on the efficiency of grafting hydrophobic polymers from cellulose nanocrystals (CNCs) via surface-initiated atom transfer radical polymerization (SI-ATRP), with the goal of producing highly-modified CNCs for incorporation into latex-based pressure sensitive adhesives (PSAs). A latex is a dispersion of polymer particles in water made by emulsion polymerization; latexes are commonly used in paints, coatings, elastomers, inks/toners, household products, cosmetics, and adhesives. However, latex-based PSAs often underperform compared to their organic solvent-polymerized counterparts due to a lack of cohesive strength in the cast latex films. The environmental benefit of using latex-based PSAs synthesized in water is significant, but the development of strategies to improve their performance are required. CNCs are hydrophilic rod-shaped nanoparticles with high mechanical strength. Adding CNCs to latex-based PSAs has been shown to improve both adhesive (i.e., tack and peel strength) and cohesive (i.e., shear strength) properties and offers a degree of sustainability because CNCs are derived from natural cellulose sources such as wood pulp. However, their hydrophilicity, particularly relative to the hydrophobic polymers used in PSAs, has constrained CNCs to the continuous (i.e., water) phase of the latex. To improve CNC compatibility with the dispersed (i.e., polymer) phase and improve their distribution in cast latex films, hydrophobic polymers can be grafted from CNCs. However, CNCs with a high polymer graft density are required to ensure their compatibility with monomers/polymers during latex synthesis. To begin, grafting poly(butyl acrylate) (PBA) from CNCs using SI-ATRP in polar dimethylformamide (DMF) versus non-polar toluene was directly compared. The enhanced colloidal stability of initiator-modified CNCs in DMF led to improved accessibility to surface initiator groups during polymer grafting. As such, PBA-grafted CNCs produced in DMF had up to 30 times more grafted polymer chains than PBA-grafted CNCs produced in toluene. The PBA-grafted CNCs produced in DMF showed high contact angles when cast in a film and formed stable suspensions in toluene. This work highlights that optimizing CNC colloidal stability in a given solvent prior to polymer grafting is a more crucial consideration than solvent–polymer compatibility in the context of obtaining high graft densities and thus hydrophobic CNCs via SI-ATRP. The improved polymer grafting method in DMF was then used to produce PBA and poly(methyl methacrylate) (PMMA)-grafted CNCs at two polymer chain lengths. Polymer grafted CNCs were incorporated in situ during a seeded semi-batch emulsion polymerization to produce PBA latex nanocomposite PSAs. Viscosity measurements revealed significant differences between latexes prepared with CNCs versus polymer-grafted CNCs, with the lower viscosities of the latter suggesting their incorporation inside the polymer particles. When CNCs with short polymer grafts were introduced into PSAs at 1 wt. % loading, they exhibited comparable tack and improved peel strength compared to unmodified CNCs (and all properties improved relative to the base latex without any CNCs). This is attributed to their improved distribution throughout the PSA, the enhanced wettability of the substrate with the CNC containing latex, and the increased polymer chain mobility achieved based on the low molecular weight of the grafts. CNCs with long polymer grafts aggregated in the latex and did not improve PSA properties. PMMA-grafted CNCs slightly outperformed PBA-grafted CNCs likely due to the higher glass transition temperature of PMMA. These results provide insight into future optimization of more sustainable latex-based PSA formulations as well as new commercial CNC-latex products, where the presence of low molecular weight grafts on CNC surfaces could improve polymer mobility and tack and peel strength.