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Styrene-acrylic copolymers emerged as important synthetic binders in the mid-20th century as emulsion polymerisation technology matured.
Combining styrene (a rigid, hydrophobic monomer) with acrylic monomers (flexible, weatherable) enabled formulators to tune hardness, Tg, film-formation, and weather resistance in waterborne systems — a critical advantage as environmental regulation and demand shifted away from solventborne systems.
Today they are among the most widely used emulsion polymers worldwide in building paints, industrial coatings, and many other sectors.
Nomenclature, synonyms & CAS identifiers
Because “styrene-acrylate” describes a class, many CAS numbers exist for particular grade definitions or specific polymer types. Common registry entries and synonyms encountered in supplier literature and databases include:
Styrene/acrylates copolymer — CAS 9010-92-8 (often used for cosmetic INCI lists).
Styrene acrylate copolymer — CAS 25034-86-0, 25767-47-9 and additional CAS variants appear for specific acrylate comonomers (e.g., butyl acrylate styrene polymer listed under 25767-47-9).
Suppliers and product datasheets list multiple CAS numbers depending on manufacturing route and composition.
Other synonyms frequently seen: styrene/acrylate emulsion, styrene acrylic resin, styrene-butyl acrylate copolymer, styrene-methyl acrylate copolymer, butyl acrylate-styrene polymer, styrene/acrylates copolymer (nano) when presented as nanoscale dispersions.
Monomers, comonomer selection and structure-property philosophy
Typical monomers:
Styrene (St) — increases rigidity, Tg, hardness, chemical resistance; hydrophobic.
Butyl acrylate (BA), Ethyl acrylate (EA), Methyl acrylate (MA) — lower Tg comonomers that impart flexibility, impact resistance and film-forming at ambient temperature.
Acrylic acid (AA), Methacrylic acid (MAA) — provide ionic/functional groups for adhesion, crosslinking sites and colloidal stability (via neutralization).
Functional acrylates — hydroxyl-, glycidyl-, or amine-functional acrylates for crosslinking and reactivity.
By varying styrene:acrylate ratio, chain architecture, and incorporation of functional comonomers one controls Tg, modulus, water-uptake, gloss, and adhesion.
Block or core-shell particles (styrene-rich shell, acrylate-rich core or vice versa) are engineered to combine surface hardness with internal flexibility and improved film formation.
Polymerisation methods
Major industrial routes:
Emulsion polymerisation — the dominant industrial process for waterborne styrene-acrylics. Advantages: good heat removal, small particle size, high molecular weight, facile control of morphology and low VOC.
Seeded emulsion, semi-continuous monomer addition, and starved-feeding techniques control particle nucleation and molecular weight.
Solution polymerisation — used for solventborne resins or for isolating polymer powders/solutions. Good for certain specialty adhesives or film-forming resins.
Bulk and suspension polymerisation — used to produce beads or powders when desired.
Process variables (surfactant type and level, initiator type, chain transfer agents, monomer feed profiles, temperature) directly affect particle morphology, molecular weight distribution and residual monomer levels.
Form types and commercial grades
Aqueous emulsions (latex) — typical solids 30–55 wt%, particle sizes 50–300 nm for standard latex; can be tailored (e.g., micronized or nanoscale). Widely used in architectural paints, adhesives.
Powder polymers / beads — for powder coatings or specialty compounding.
Solution resins — solventborne adhesives / coatings.
Reactive/acrylic hybrids — with functional groups for crosslinking (isocyanate, melamine, aziridine curatives).
Physical & chemical properties
Glass transition temperature (Tg): tunable from well below 0 °C to >100 °C depending on styrene content and acrylate selection. Higher styrene raises Tg and hardness.
Particle morphology: core-shell, gradient, random; morphology affects film formation and mechanical properties.
Solubility: Generally insoluble in water (as polymer), dispersed as latex; soluble in aromatic/ketone solvents depending on composition.
Thermal stability: reasonable for many coating applications; decomposition temperatures typically above 250–300 °C for backbone degradation.
Residual monomer content: typically controlled to low ppm levels for safety/performance; residual styrene often the focus of monitoring
SAFETY INFORMATION ABOUT STYRENE ACRYLATES COPOLYMER
First aid measures:
Description of first aid measures:
General advice:
Consult a physician.
Show this safety data sheet to the doctor in attendance.
Move out of dangerous area:
If inhaled:
If breathed in, move person into fresh air.
If not breathing, give artificial respiration.
Consult a physician.
In case of skin contact:
Take off contaminated clothing and shoes immediately.
Wash off with soap and plenty of water.
Consult a physician.
In case of eye contact:
Rinse thoroughly with plenty of water for at least 15 minutes and consult a physician.
Continue rinsing eyes during transport to hospital.
If swallowed:
Do NOT induce vomiting.
Never give anything by mouth to an unconscious person.
Rinse mouth with water.
Consult a physician.
Firefighting measures:
Extinguishing media:
Suitable extinguishing media:
Use water spray, alcohol-resistant foam, dry chemical or carbon dioxide.
Special hazards arising from the substance or mixture
Carbon oxides, Nitrogen oxides (NOx), Hydrogen chloride gas
Advice for firefighters:
Wear self-contained breathing apparatus for firefighting if necessary.
Accidental release measures:
Personal precautions, protective equipment and emergency procedures
Use personal protective equipment.
Avoid breathing vapours, mist or gas.
Evacuate personnel to safe areas.
Environmental precautions:
Prevent further leakage or spillage if safe to do so.
Do not let product enter drains.
Discharge into the environment must be avoided.
Methods and materials for containment and cleaning up:
Soak up with inert absorbent material and dispose of as hazardous waste.
Keep in suitable, closed containers for disposal.
Handling and storage:
Precautions for safe handling:
Avoid inhalation of vapour or mist.
Conditions for safe storage, including any incompatibilities:
Keep container tightly closed in a dry and well-ventilated place.
Containers which are opened must be carefully resealed and kept upright to prevent leakage.
Storage class (TRGS 510): 8A: Combustible, corrosive hazardous materials
Exposure controls/personal protection:
Control parameters:
Components with workplace control parameters
Contains no substances with occupational exposure limit values.
Exposure controls:
Appropriate engineering controls:
Handle in accordance with good industrial hygiene and safety practice.
Wash hands before breaks and at the end of workday.
Personal protective equipment:
Eye/face protection:
Tightly fitting safety goggles.
Faceshield (8-inch minimum).
Use equipment for eye protection tested and approved under appropriate government standards such as NIOSH (US) or EN 166(EU).
Skin protection:
Handle with gloves.
Gloves must be inspected prior to use.
Use proper glove
removal technique (without touching glove's outer surface) to avoid skin contact with this product.
Dispose of contaminated gloves after use in accordance with applicable laws and good laboratory practices.
Wash and dry hands.
Full contact:
Material: Nitrile rubber
Minimum layer thickness: 0.11 mm
Break through time: 480 min
Material tested:Dermatril (KCL 740 / Aldrich Z677272, Size M)
Splash contact
Material: Nitrile rubber
Minimum layer thickness: 0.11 mm
Break through time: 480 min
Material tested:Dermatril (KCL 740 / Aldrich Z677272, Size M)
It should not be construed as offering an approval for any specific use scenario.
Body Protection:
Complete suit protecting against chemicals, The type of protective equipment must be selected according to the concentration and amount of the dangerous substance at the specific workplace.
Respiratory protection:
Where risk assessment shows air-purifying respirators are appropriate use a fullface respirator with multi-purpose combination (US) or type ABEK (EN 14387) respirator cartridges as a backup to engineering controls.
If the respirator is the sole means of protection, use a full-face supplied air respirator.
Use respirators and components tested and approved under appropriate government standards such as NIOSH (US) or CEN (EU).
Control of environmental exposure
Prevent further leakage or spillage if safe to do so.
Do not let product enter drains.
Discharge into the environment must be avoided.
Stability and reactivity:
Chemical stability:
Stable under recommended storage conditions.
Incompatible materials:
Strong oxidizing agents:
Hazardous decomposition products:
Hazardous decomposition products formed under fire conditions.
Carbon oxides, Nitrogen oxides (NOx), Hydrogen chloride gas.
Disposal considerations:
Waste treatment methods:
Product:
Offer surplus and non-recyclable solutions to a licensed disposal company.
Contact a licensed professional waste disposal service to dispose of this material.
Contaminated packaging:
Dispose of as unused product
