Overcoming Challenges of Incorporation of Biobased Dibutyl Itaconate in (Meth)acrylic Waterborne Polymers

Polymeric derivatives of itaconic acid are gaining interest as biobased alternatives to petroleum-based monomers due to their versatility, renewable nature, commercial availability, and cost-effectiveness. Itaconate ester monomer's challenges incorporating in (meth)acrylic waterborne polymers are the low propagation rate, unfavorable reactivity ratios, and the depropagation process. To overcome these challenges, the seeded semibatch emulsion polymerization of 100% biobased dibutyl itaconate, methyl methacrylate, and butyl acrylate was investigated at different temperatures. Consequently, 30 wt % DBI was successfully incorporated within waterborne (meth)acrylates in short reaction times (4 h), obtaining high DBI incorporation (>90%). The results demonstrate that DBI incorporation influences the instantaneous monomer conversion, polymer's microstructure, and mechanical properties. By incorporating a biobased itaconate cross-linker, kinetics and mechanical characteristics of the polymers were improved. This combined approach can be implemented without altering industrial processes, resolving the commercialization dilemma for itaconate monomers to synthesize high-performance biobased polymers for adhesive and coating industries.