Binder-consolidated textile fabric, method for its manufacture and its use
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Solution Overview
Problem
Current binder systems for consolidating textile fabrics used in coated materials and building applications lack improved color stability, wet strength, and cost-effectiveness, while also requiring compliance with environmental regulations and using predominantly renewable raw materials.
Innovation Solution
A binder system comprising 0.1-30% polyvinyl alcohol polymers and at least 70% of a mixture containing a carbohydrate and an α-carbon nucleophile crosslinking agent, with a minimum of 50% reducing sugars, along with optional crosslinkers, fillers, and additives, to achieve enhanced mechanical and thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional thermoplastic and thermoset binder systems are used for consolidating textile fabrics, then mechanical stability and thermal resistance are achieved, but color stability deteriorates over time and wet strength is insufficient
Solution Approach 1:
The invention changes the chemical parameters of the binder system by using polyvinyl alcohol polymers with specific degrees of saponification (70-99%) and molecular weights (10,000-2,000,000), combined with specific crosslinking agents. This parameter optimization resolves the contradiction by achieving both improved wet strength and enhanced color stability through controlled polymer chemistry.
Solution Approach 2:
The invention creates a composite binder system combining polyvinyl alcohol polymers with crosslinking agents (such as borax, zinc chloride, or organic crosslinkers). This composite approach resolves the contradiction by synergistically combining the adhesive properties of PVA with the stabilizing effects of crosslinking, achieving both wet strength and long-term color stability.
2Temperature
If starch-based binder systems are used to achieve good heat resistance, then thermal stability is improved, but wet strength and color stability remain insufficient
Solution Approach 1:
The invention transitions from starch-based binders to polyvinyl alcohol-based binders with controlled saponification degrees and molecular weights. This parameter change resolves the contradiction by maintaining thermal stability through the crystalline structure of PVA while significantly improving wet strength through hydrogen bonding and crosslinking mechanisms.
Solution Approach 2:
The invention replaces expensive, performance-limited starch-based systems with cost-effective polyvinyl alcohol polymers that can be applied at higher solids concentrations (5-50% dry binder). This resolves the contradiction by providing a more economical solution that delivers superior wet strength and color stability without sacrificing heat resistance.
3Adaptability or versatility
If binder systems with high renewable raw material content are developed to meet environmental regulations, then environmental compliance is improved, but manufacturing cost increases
Solution Approach 1:
The invention optimizes the parameters of polyvinyl alcohol polymers (saponification degree, molecular weight) to achieve maximum performance at minimum cost. This resolves the contradiction by providing a renewable, environmentally compliant binder system that is economically viable through efficient use of raw materials and reduced application requirements.
Solution Approach 2:
The invention applies binder systems with localized high solids concentration (5-50% dry binder) directly where needed on the textile fabric. This resolves the contradiction by reducing overall material consumption and manufacturing costs while maintaining environmental compliance through the use of renewable PVA-based materials.
4Adaptability or versatility
If existing binder systems are replaced to comply with new environmental regulations (DIN EN 14041, REACH), then legal compliance is improved, but production complexity increases
Solution Approach 1:
The invention creates a universal binder system based on polyvinyl alcohol polymers that can be applied to various textile substrates and processed through existing manufacturing equipment. This resolves the contradiction by providing a single, multi-functional solution that ensures regulatory compliance across different applications without increasing production complexity.
Solution Approach 2:
The binder system is designed to be self-applicable through existing production lines using standard methods (dipping, coating, or spraying). This resolves the contradiction by enabling easy integration into current manufacturing processes without requiring complex new equipment or procedures, thus maintaining production simplicity while achieving regulatory compliance.
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 provides improved wet strength, thermal stability, and color stability, while being economically accessible and environmentally compliant, with reduced moisture uptake and brittleness, allowing for high solids concentration application without compromising mechanical properties.
Implementation Method 1
an α-carbon atom directly bonded to the first carbon moiety, the α-carbon atom has at least one acidic hydrogen atom and the α-carbon atom forms a nucleophile that reacts with a carbonyl carbon on the carbohydrate during polymerization of the binder composition to form the cured binder
Implementation Method 2
binder system for consolidating textile surfaces
Data Source
Figure 1
AI summary
The invention concerns a novel binder system and its use for consolidating textile fabrics, as well as to products containing such consolidated textile fabrics. The materials according to the invention are suitable for the manufacture of reinforcing inserts, optionally in combination with at least one further textile fabric, for coated sarking membranes, roofing and waterproofing sheets, as textile backings or textile reinforcement in flooring, in particular in fitted carpets and PVC flooring, or in facers in wall coatings both in the interior and exterior of buildings, as well as in furniture.