Curable aqueous composition
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Solution Overview
Problem
Existing methods for treating flexible substrates with formaldehyde-free compositions, using emulsion polymers with copolymerized ethylenically-unsaturated dicarboxylic acid monomers and polyols, do not achieve optimal properties such as superior cure, wash durability, and solvent resistance.
Innovation Solution
A curable aqueous composition comprising an emulsion polymer with 0.5 to 9% ethylenically-unsaturated dicarboxylic acid monomer and 0.5 to 15% polyol by weight, optionally including a phosphorous-containing species, is used to treat flexible substrates by heating the composition between 120°C to 220°C, forming a treated substrate with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing methods use emulsion polymers with copolymerized ethylenically-unsaturated dicarboxylic acid monomers and polyols to treat flexible substrates, then the composition remains formaldehyde-free, but the properties such as cure, wash durability, and solvent resistance are not optimal
Solution Approach 1:
The patent optimizes the carboxylic acid monomer content parameter to 0.5-9% in the emulsion polymer and the polyol content to 0.5-15% by weight, creating a specific compositional range that achieves superior cure and durability without formaldehyde. This parameter optimization resolves the contradiction by finding the optimal balance point that delivers high performance while maintaining formaldehyde-free status.
2Strength
If the carboxylic acid monomer content is increased to improve cure properties, then the binding efficiency improves, but the composition may generate formaldehyde
Solution Approach 1:
The patent establishes a specific parameter range for carboxylic acid monomer content (0.5-9%) that maximizes binding strength through optimized molecular interactions while preventing formaldehyde generation. This controlled parameter range ensures that the chemical composition provides sufficient reactivity for strong binding without exceeding the threshold that would trigger formaldehyde formation.
3Reliability
If polyol content is increased to improve wash durability, then the solvent resistance improves, but the composition complexity increases
Solution Approach 1:
The patent optimizes polyol content to a specific range (0.5-15% by weight) that achieves maximum wash durability and solvent resistance. Within this optimized range, the polyol forms an effective protective network that enhances durability without requiring excessive amounts that would complicate the composition formulation and processing.
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 treated substrate exhibits superior cure, wash durability, and solvent resistance, maintaining a formaldehyde-free composition and process.
Implementation Method 1
a curable aqueous composition... heating the composition between 120°C to 220°C, forming a treated substrate with improved properties... exhibits superior cure
Data Source
AI summary
A curable aqueous composition, a method for forming a treated substrate with the curable aqueous composition, and the substrate so treated are provided. The curable aqueous composition, the process for forming a treated substrate and the treated substrate may be free from formaldehyde. The curable aqueous composition includes: an emulsion polymer including, as copolymerized units, from 0.5 to 9% ethylenically-unsaturated dicarboxylic acid monomer by weight, based on the weight of the emulsion polymer; and a polyol in the amount of from 0.5 to 15%, by weight, based on the weight of the emulsion polymer, wherein the aqueous composition includes carboxylic acid-containing polymer including, as polymerized units, from 0.5 to 9% carboxylic acid monomer by weight, based on the total weight of the carboxylic acid-containing polymer.