Base Interlining Binder Composition for Heat-Stable Roofing Membranes

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Solution Overview

Problem

Textile fabrics used as base interlinings for roofing membranes lack sufficient mechanical stability, heat stability, and resistance to fire, while existing improvements increase manufacturing costs.

Innovation Solution

A binder system comprising 10-90 wt% of an aqueous dispersion of polymerizates based on conjugated aliphatic dienes and vinyl aromatic compounds, 90-10 wt% starch, and up to 10 wt% additives, which enhances heat dimensional stability and maintains flexibility and ageing characteristics without increasing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional binder systems are used to bond non-woven fabrics and reinforcing fibers, then mechanical stability is improved, but heat dimensional stability deteriorates

Engineering Contradiction:

Improvemechanical stabilityVSAvoidheat dimensional stability

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The patent changes the chemical composition parameters of the binder system by incorporating starch (90-10 wt%) combined with aqueous dispersion of polymerisates (10-90 wt%). This compositional parameter change enables the binder to maintain both mechanical bonding strength and heat dimensional stability, resolving the contradiction between these two properties.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses a composite binder system combining starch and polymerisate dispersion rather than a single binder material. This composite approach allows the starch component to provide heat stability while the polymerisate component ensures mechanical bonding, thus achieving both improved mechanical stability and heat dimensional stability simultaneously.

Inventive Principle:

Principle #40Composite materials

2Strength

If reinforcement fibers are added to improve mechanical stability, then tensile strength is improved, but manufacturing cost increases

Engineering Contradiction:

Improvetensile strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent modifies the binder composition parameters to include a high starch content (90-10 wt%) which provides cost-effective bonding compared to conventional synthetic binders. This parameter change in binder chemistry allows adequate mechanical stability and tensile strength to be achieved without proportionally increasing manufacturing costs, as starch is a more economical material option.

Inventive Principle:

Principle #35Parameter changes

3Strength

If synthetic binders are used to ensure mechanical stability, then bonding strength is improved, but formaldehyde emission increases

Engineering Contradiction:

Improvebonding strengthVSAvoidformaldehyde emission

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent replaces persistent synthetic binders with starch-based binders that are biodegradable and do not emit formaldehyde. Although starch may have shorter-term stability concerns, the combination with polymerisate dispersion provides adequate bonding strength while eliminating harmful formaldehyde emissions, thus resolving the contradiction between bonding strength and harmful emissions.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention converts the potential weakness of starch (lower bonding strength compared to synthetic binders) into a benefit by combining it with polymerisate dispersion, creating a synergistic effect that provides sufficient bonding strength while eliminating formaldehyde emission. The starch component specifically addresses the harmful emission issue while the polymerisate compensates for any bonding strength deficits.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 system significantly improves heat dimensional stability and maintains flexibility and ageing characteristics, achieving cost savings by partly using starch, and results in a formaldehyde-free binder system with improved product properties.

Implementation Method 1

textile fabric being solidified by means of a special binder system, comprising: a) 10 to 90 wt % of an aqueous dispersion of polymerisates based on conjugated aliphatic dienes and vinyl aromatic compounds

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

in spite of water absorption the ageing characteristics, the flexibility or stabilities have not significantly declined

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS10260197B2Base interlining, methods for their manufacture and application thereof

Publication Date: 2019.04.16 JOHNS MANVILLE CORP

AI summary

The invention relates to a novel binder system and its use for bonding textile fabrics as well as products containing such bonded textile fabrics. The materials according to the invention are suitable for manufacturing base interlinings which may be used for manufacturing base interlinings for sarking, roofing and sealing membranes, particularly for manufacturing coated sarking, roofing and sealing membranes.