Aqueous Binder Compositions for Low-Loss, Humidity-Resistant Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing binder compositions based on polyester chemistry or the condensation of ammonium salts of inorganic acids or polycarboxylic acids with reducing sugars suffer from high binder weight loss upon heat exposure, undesirable degradation in humid environments, and inadequate bond strength, necessitating improved binder chemistry for better cohesion and cost-effectiveness.
Innovation Solution
Aqueous curable binder compositions incorporating matrix polymers such as polysaccharides, polyacrylates, and polyurethanes, along with polycarboxylic acids and ammonium salts, form thermoset resins that enhance bond strength and reduce binder loss, utilizing renewable resources and rapid curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyester chemistry or condensation of ammonium salts with reducing sugars is used as binder composition, then bond strength is improved, but binder weight loss upon heat exposure increases
Solution Approach 1:
The patent combines multiple binder components (polyester chemistry components and condensation components) to create a composite binder system that leverages the strengths of each chemistry type while mitigating their individual weaknesses, particularly reducing weight loss while maintaining bond strength
2Strength
If polyester chemistry or condensation of ammonium salts with reducing sugars is used as binder composition, then bond strength is improved, but degradation in humid environments occurs
Solution Approach 1:
The patent modifies the chemical parameters of the binder composition by incorporating hydrophobic components and adjusting the ratio of hydrophilic to hydrophobic substances, thereby changing the binder's resistance to moisture and improving its stability in humid environments while preserving bond strength
3Strength
If conventional binder compositions are used, then manufacturing cost is reduced, but bond strength is inadequate
Solution Approach 1:
The patent optimizes the formulation parameters by adjusting the ratios of different binder components and selecting cost-effective materials that provide adequate bond strength, thereby balancing performance requirements with manufacturing cost considerations
4Ease of manufacture
If binder content is reduced to lower cost, then manufacturing cost is reduced, but bond strength decreases
Solution Approach 1:
The patent creates a composite binder system where synergistic interactions between components enhance the efficiency of the binder, allowing for reduced binder content while maintaining or improving bond strength through the combined effects of multiple chemistry types
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The compositions demonstrate significantly improved bond strength and reduced water absorption, maintaining strength even after weathering, while being cost-effective and environmentally friendly, with matrix polymers like chitosan and carboxymethyl cellulose enhancing the performance.
Implementation Method 1
the condensation of ammonium salt of inorganic acids or of polycarboxylic acids or an amine, preferably a polyamine, with reducing sugars as thermosets
Data Source
AI summary
The present invention relates to new aqueous binder compositions comprising an aqueous curable binder composition comprising starting materials required for forming a thermoset resin upon curing and a matrix polymer, wherein the starting materials required for forming a thermoset resin upon curing comprise (i) a polyhydroxy component and a polycarboxylic acid component, or an anhydride, ester or salt derivative thereof and/or reaction product thereof, or (ii) a carbohydrate component and a nitrogen containing component and/or a reaction product thereof.