Introduction to Vinyl Acetate Ethylene (VAE)

Vinyl acetate ethylene (VAE) copolymer dispersions are created through emulsion polymerization, combining vinyl acetate and ethylene monomers. This process occurs in water, resulting in milk-like latex emulsions. Vinyl acetate, a hard monomer, forms poly(vinyl acetate) upon polymerization and is extensively utilized in adhesives. The addition of ethylene as a comonomer significantly reduces the glass transition temperature of the final VAE copolymer, eliminating the need for plasticizers prone to migration. Ethylene enhances the copolymer's flexibility, toughness, adhesion, and durability and reduces water sensitivity (making it more hydrophobic). VAE dispersions offer environmental benefits, demonstrating excellent film-forming properties without requiring coalescing agents, as seen in low VOC paints and coatings.

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VAE dispersions can be transformed into powders through spray drying. These VAE polymer powders retain their properties and can easily redisperse in water.

The primary consumers of VAE RDP are the building and construction sectors, as they are integral to formulating dry mix products. It's projected that the global market for these products will grow by over 7%. Innovations in thin layer tile adhesives are one of the primary catalysts for this market expansion.

Vinyl acetate-co-polyethylene copolymer (VAE) in powder form is a white, free-flowing powder that can be easily redispersed in water to recreate a stable emulsion. Often called "solid latex,” VAE redispersible powders (RDP) are easier to transport, store (owing to their excellent storage stability), handle, and dry blend compared to VAE in emulsion form. VAE dominates the global market for redispersible polymer powders.

Adding VAE-RDP to dry blend formulations yields benefits such as enhanced workability, water retention, plasticity, dispersibility, and freeze stability. Due to the relatively high ethylene content, VAE resins are soft and flexible. As a modifier, VAE-RDP augments flexural strength, crack resistance, adhesion, abrasion and impact resistance, and water resistance.

Vinyl acetate and ethylene undergo emulsion polymerization to yield a VAE composition with 10% to 40% ethylene in the copolymer. Ethylene, a soft, hydrophobic monomeric unit, serves as the copolymer’s internal "plasticizing" component.

In the copolymer, ethylene effectively lowers the glass transition temperature (Tg) of the hard, polar vinyl acetate monomer to approximately 30°C. Consequently, we achieve copolymers with Tg ranging from +15°C to -15°C, transforming the base emulsion resin used in VAE production into a redispersible powder. Ethylene monomers regulate Tg, eliminating the need for external plasticizers.

The manufacturing process for redispersible powders begins with a VAE emulsion stabilized with colloidal agents like polyvinyl alcohol. This emulsion is blended with a fine mineral anti-caking agent and then spray dried. The outcome is a stable, free-flowing powder that redisperses upon mixing with water. The minimum solids content of RDP is 98%, and the anti-caking agent content ranges from 8-12% of the total weight. These VAEs have minimal volatile organic compound (VOC) content and low odor levels.

VAE-RDP is used for formulating building materials like tile adhesives, grouting, finishing plasters, smoothing compounds, thin mortars, and sealing pastes. Depending on the desired improvement in strength, impact resistance, adhesion, and water resistance, VAE-RDP is added to cement and mortar in amounts ranging from 2-10%.

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For wall tile adhesives, VAE-RDP enhances slump, water retention, and workability, enabling top-to-bottom tile placement without slippage or the need for shims. VAE-RDP also improves the leveling properties of tile adhesives and other cementitious materials.

The demand for VAE-RDP has expanded into surface coating compounds, where it helps boost wall adhesion and crack bridging properties.

In oil and gas well cementing operations, polymer powder/cement combinations improve rheological properties and durability while reducing water loss in cement slurries and oilfield fluids. The powder enhances gas migration control in the cement slurry with minimal effects on extending the setting time.

By improving particle-to-particle bonding, hardened cement/polymer composites exhibit enhanced flexibility and strength, as well as increased adhesion and durability. For on-site operations, VAE dispersible powders offer benefits in handling, storage, and on-site mixing, while enhancing water retention, workability, and mechanical strength, and reducing the permeability of the cementitious material.

VAE/RDP Applications and Grades

VAE-RDP grades and general applications are identifiable by their glass transition temperature (Tg)—the pivotal temperature at which amorphous polymers like VAE switch from a glassy solid to a rubbery state. Above Tg, the polymer turns rubbery; below Tg, it becomes glass-like.

The VAE-RDP spectrum ranges from low Tg soft materials (DA 1400 series) to medium Tg flexible materials (DA-1200 series) to high Tg hard materials (DA 1100 series).

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