Latex dispersions having a well-controlled, bimodal particle size distribution are gaining attention because they potentially enable control of the dispersion rheology, the film formation characteristics, and the final film properties. Here we study the film formation of dispersions with a bimodal particle size distribution (large:small size ratio of ca. 6:1) and with varying concentrations of the two particle sizes. We also compare the film formation of blends containing only deformable (i.e., “soft”) particles with blends containing both soft and nondeformable (i.e., “hard”) particles. We use ellipsometry as a noninvasive tool for studying film morphology as film formation proceeds. We interpret our ellipsometry data using a physical model of the morphology based on atomic force microscopy observation. Electron microscopy of film cross sections provides information about the bulk morphology. We measure void content and surface roughness in blend films as a function of the concentration of large particle...
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