Fibre products with a coating made formed from aqueous polymer dispersions
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Solution Overview
Problem
Current textile-reinforced concrete systems face limitations in temperature resistance and alkaline resistance, particularly with existing polymer coatings, which restrict their use to indoor applications and temperatures below 40°C, and require long anchoring lengths for adequate bonding, limiting their practical usability and outdoor applications.
Innovation Solution
A composite material using a textile fiber product coated with an aqueous polymer dispersion based on ethylenically polymerizable monomers with a glass transition temperature of at least 60°C, applied in a continuous process, providing enhanced tensile strength and bonding properties suitable for mineral matrices, allowing for windable and drapeable reinforcement structures that maintain performance from -30°C to 100°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If existing polymer coatings with low glass transition temperature are used, then the coating remains flexible and easy to apply, but the temperature resistance is limited to below 40°C and alkaline resistance is insufficient
Solution Approach 1:
The patent changes the glass transition temperature parameter of the polymer coating from below 40°C to at least 60°C by selecting specific monomers (styrene, (meth)acrylonitrile, (meth)acrylic acid) and controlling their ratios. This parameter change enables the coating to maintain its protective functions at elevated temperatures up to 100°C while still providing adequate flexibility and adhesion.
Solution Approach 2:
The patent creates a composite polymer system by copolymerizing multiple monomers with different properties: styrene provides high glass transition temperature and thermal stability, (meth)acrylonitrile contributes to chemical resistance and mechanical strength, and (meth)acrylic acid provides adhesion to mineral substrates. This composite approach achieves both high temperature resistance and adequate versatility.
2Reliability
If textile reinforcement structures are used for outdoor applications, then corrosion protection is needed, but existing coatings fail to provide sufficient resistance to alkaline environments and high temperatures
Solution Approach 1:
The patent modifies the chemical composition parameters of the polymer coating by incorporating (meth)acrylonitrile units which provide excellent chemical resistance, and adjusting the monomer ratios to achieve optimal balance between adhesion, flexibility, and chemical resistance. This enables the coating to withstand alkaline concrete environments for outdoor applications.
Solution Approach 2:
The patent uses a water-based polymer dispersion that forms a protective coating on the textile reinforcement, replacing the need for thick concrete covers. The coating acts as a durable, cost-effective protective layer that extends the service life of the reinforcement in outdoor alkaline environments.
3Strength
If conventional coating processes are used, then the coating can be applied to fiber products, but the bonding strength to mineral matrices is insufficient and long anchoring lengths are required
Solution Approach 1:
The patent changes the surface chemical parameters of the coating by incorporating (meth)acrylic acid units that provide carboxyl groups for strong chemical bonding to mineral substrates like concrete and mortar. This parameter change in chemical composition enables high bonding strength with short anchoring lengths, improving the efficiency of the composite material.
Solution Approach 2:
The patent replaces mechanical bonding (which would require long anchoring lengths) with chemical bonding through the polymer coating. The functional groups in the polymer (carboxyl, nitrile) form strong chemical bonds with the mineral matrix, substituting mechanical interlocking with molecular-level adhesion, thereby achieving high strength with shorter anchoring lengths.
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 solution achieves tensile strengths greater than 3000 MPa for carbon fiber rovings and maintains composite properties across a wide temperature range, ensuring resistance to alkaline environments, enabling outdoor applications and reducing material usage while maintaining structural integrity.
Implementation Method 1
provides an aqueous polymer dispersion based on ethylenically, in particular vinylically polymerizable, monomers with a glass transition temperature of at least 60 °C, brings it into contact with a fiber product and then dries it
Implementation Method 2
polymers based on ethylenically polymerizable monomers with a glass transition temperature of at least 60 °C
Implementation Method 3
The fiber products are available in particular with a coating process for coating fiber products with an aqueous polymer dispersion
Data Source
Figure 1
AI summary
The present invention relates to textile fibre products having a coating comprising polymers based on ethylenically polymerisable monomers with a glass transition temperature of at least 60° and a coating method for coating fibre products with an aqueous polymer dispersion, wherein an aqueous polymer dispersion based on vinyl polymerisable monomers with a glass transition temperature of at least 60°C is firstly provided, and this is brought into contact with a fibre product and then dried. The invention also relates to the use of corresponding polymer dispersions for the coating of fibre products, correspondingly coated fiber products, use thereof to reinforce mineral matrices, and corresponding fibre-composite materials, in particular textile-concrete composite materials. In particular, the invention relates to a coating means that can be applied to a textile fabric in a continuous, water-based process and enables an optimal introduction of force from the mineral matrix into the textile reinforcement.