Aqueous binder composition
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Solution Overview
Problem
Existing binder systems for fibrous and granular substrates often rely on formaldehyde-releasing agents, leading to undesirable formaldehyde emissions, and alternative systems may not fully meet mechanical properties such as tensile strength and heat resistance, while there is a growing demand for formaldehyde-free or reduced formaldehyde solutions based on renewable raw materials.
Innovation Solution
An aqueous binder composition comprising a polymer made from specific monoethylenically unsaturated compounds and lignin, optimized to achieve improved mechanical properties and heat stability, is developed. The polymer includes monomers with silicon-containing, epoxy, hydroxyalkyl, or carbonyl groups, along with mono- and dicarboxylic acids, and lignin compounds, formulated to enhance tear strength and heat resistance without formaldehyde emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If formaldehyde-releasing crosslinkers are used to increase tensile strength and heat resistance, then mechanical strength is improved, but formaldehyde emissions occur
Solution Approach 1:
The patent extracts and removes the harmful formaldehyde-releasing crosslinkers from the binder system, replacing them with alternative crosslinking agents (isocyanates, carboxylic acids with polyols, or silanes) that achieve the same mechanical strengthening function without generating formaldehyde emissions
Solution Approach 2:
The patent changes the chemical composition parameters of the binder system by specifying precise monomer ratios (monomers A: 0.1-10 wt%, monomers B: 0-20 wt%, monomers C: 70-95 wt%) and polymer properties (glass transition temperature 10-50°C, weight-average molecular weight 50,000-500,000) to achieve optimal mechanical strength without formaldehyde
2Object-generated harmful factors
If formaldehyde-free alternative binders are used to avoid emissions, then harmful emissions are reduced, but mechanical strength and heat resistance are insufficient
Solution Approach 1:
The patent creates a composite binder system combining specifically formulated polymers (with controlled Tg and molecular weight) and lignin compounds in optimized ratios (10-60 parts lignin per 100 parts polymer), where the synergistic interaction between components achieves both formaldehyde-free operation and high mechanical strength
Solution Approach 2:
The patent optimizes multiple parameters simultaneously: polymer glass transition temperature (10-50°C), molecular weight (50,000-500,000), lignin content (10-60 parts per 100 parts polymer), and monomer composition to achieve the desired balance between environmental compatibility and mechanical performance
3Reliability
If renewable raw materials are used to reduce environmental impact, then sustainability is improved, but performance consistency may be compromised
Solution Approach 1:
The patent establishes precise parameter ranges for renewable polymer components (glass transition temperature 10-50°C, weight-average molecular weight 50,000-500,000) that ensure consistent mechanical performance while maintaining sustainability, and optimizes the lignin content (10-60 parts per 100 parts polymer) to achieve reliable strength
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 binder composition achieves equivalent or improved mechanical properties, including enhanced tear strength and heat stability, while being formaldehyde-free or reduced, utilizing renewable raw materials and avoiding the use of formaldehyde-releasing agents.
Implementation Method 1
An aqueous binder composition, containing as essential binder components a) at least one polymer P... and b) at least one lignin compound L... The invention further includes the use of the aqueous binder composition as a binder for granular and/or fibrous substrates
Data Source
AI summary
Aqueous binder composition for granular and/or fibrous substrates.