Why is it necessary to control the amount of acrylate toughening agent in PVC foam formulations?

Toughening agents (typically core-shell rubber or acrylates) improve the impact strength and elongation at break of PVC foam. However, excessive addition (above 10 phr) lowers the glass transition temperature, causing the foam to soften when used above 40°C and increasing compressive creep. Furthermore, the toughening agent has limited compatibility with PVC resin, forming island phases on cell walls and reducing shear modulus. The optimal dosage (by resin weight) is 5–8 phr, at which notched impact strength increases from 4 kJ/m² to 12 kJ/m², while compressive strength loss is kept below 15%. Engineering applications require balancing toughness and rigidity through drop-ball impact and composite shear testing.

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Why is it necessary to control the amount of acrylate toughening agent in PVC foam formulations?

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