JoPC (2015) 11-21 © STM Journals 2015. All Rights Reserved Page 11 Journal of Polymer & Composites ISSN: 2321-2810(online), ISSN: 2321-8525(print) Volume 3, Issue 2 www.stmjournals.com Synthesis and Characterization of Emulsion Paint Binder from a Copolymer Composite of Dimethylol Urea/Polystyrene S.A. Osemeahon, I.I. Nkafamiya, O.N. Maitera, A. Akinterinwa* Department of Chemistry, Modibbo Adama University of Technology, Yola, Adamawa State, Nigeria Abstract In our desire to reduce formaldehyde emission from urea formaldehyde resin (UF), dimethylol urea (DMU) was synthesized. Liquid polystyrene (PS) obtained from waste PS material was copolymerized by blending with the DMU at varying concentrations (10–70%). Infrared spectra infers a reactive blending between DMU and PS, while some physical property tests carried out reveals reduction in moisture uptake, rigidity and further reduction in formaldehyde emission among the favorable changes in the properties of the DMU/PS copolymer composite compared to the pure DMU. Results obtained from the physical characterization were compared with those reported for some binders in the coating industry to further ascertain the quality of the DMU/PS copolymer composite. The results portray DMU/PS copolymer resin as a binder for emulsion paint formulation. Keywords: Urea formaldehyde, polystyrenes, copolymer composite, paint binder *Author for Correspondence E-mail: ayoterinwa@yahoo.com, INTRODUCTION The life of a paint is that of the binder from which it is made. Binder also referred to as film-former, could be a drying oil, pure synthetic resin, or a mixture of these [1]. Many properties of paint such as pigment dispersion, brushability, flow, leveling and sagging etc., depend on the nature, quality and the properties of the binder used [2]. Some paint/coatings are also named after the binder component e.g. epoxies paints, chlorinated rubber paints, alkyd paints, etc. Water based paints (WBPs) and oil based paints (OBPs) are the two classes of paint based on the solvent. WBPs are odorless, cheap, easily dried, easily applied and non- flammable. The binders used are soluble or dispersible in water [3]. OBPs exhibit such good properties as; good chemical, water, weather and heat resistance, adhesion, full gloss and flexibility. The binders are soluble or dispersible in solvents other than water [4]. These solvents include ketones, alcohols, esters, ethers, ketones and chlorinated hydrocarbons and they are referred to as volatile organic compounds (VOCs). For paint to adhere appropriately to the surface unto which it is applied and form a solid film, the solvent must dry-off in the presence of air and/or light, hence the release of these substances (VOCs) into the atmosphere [4]. Above some threshold concentrations produced from coating surfaces, VOCs are unfriendly to life generally and particularly human health and environment [5]. This has placed restrictions on VOCs by regulatory bodies all over the world [6]. Due to this, more focus has been on the development of WBPs with properties that can be compared with those qualities associated with OBPs. Methylol urea is a synthetic product of the reaction between urea and formaldehyde. The resin exhibits such properties as; solubility in water, fast curing, formation of hard, clear, colourless, glossy and water insoluble film when cured, low cost, good electrical resistance, and zero impact on food and beverages it comes in contact with when cured [7]. It also offers a wide range of conditions that makes it possible to be synthesized while optimizing such important properties as; gel time, tack and spreadability of the resin [8]. These properties present it as a potential binder in paint and adhesive applications.