Formaldehyde-Free Crosslinking Polymer Composition

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Solution Overview

Problem

Current aqueous polymer dispersions used for bonding and coating applications often suffer from reduced adhesion and cohesion when exposed to water, solvents, and mechanical stress, and they may release hazardous formaldehyde during crosslinking, which is a concern due to its irritant and carcinogenic properties.

Innovation Solution

A curable polymer composition comprising a triplet of functional monomers - a nitrogen-functional monomer, an oxygen-functional monomer, and an acid-functional monomer - that can crosslink at conventional industrial temperatures without releasing formaldehyde, using methacrylamide, hydroxyethyl methacrylate, glycidyl methacrylate, and itaconic acid, along with other ethylenically unsaturated monomers to form a polymeric backbone.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If N-methylol-acrylamide (NMA) is used as a crosslinking monomer to improve film strength and cohesion, then bonding strength is improved, but formaldehyde is released which is hazardous and carcinogenic

Engineering Contradiction:

Improvebonding strengthVSAvoidformaldehyde release

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and removes the harmful formaldehyde component from the crosslinking system while retaining the beneficial crosslinking functionality. This is achieved by replacing NMA with alternative crosslinking monomers that do not release formaldehyde, thereby eliminating the harmful effect while preserving the bonding strength improvement.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs temporary protective colloids and emulsifiers that are consumed or transformed during the polymerization and crosslinking process. These short-living components facilitate the reaction but are not present in the final cured product, allowing effective crosslinking without persistent harmful residues.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If crosslinking monomers are added to improve adhesion and cohesion resistance, then water and solvent resistance is improved, but the system becomes more complex and may release hazardous materials

Engineering Contradiction:

Improvewater and solvent resistanceVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent develops polymer dispersions that achieve multiple functions simultaneously: the polymer provides adhesion and cohesion, while integrated crosslinking monomers provide water and solvent resistance. This multi-functional approach eliminates the need for separate additive systems, reducing overall system complexity while maintaining reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent creates composite polymer systems combining base polymer chains with crosslinked networks formed by functional monomers. This composite structure integrates the benefits of both linear polymer adhesion and crosslinked network resistance to water and solvents, achieving enhanced reliability without proportionally increasing complexity.

Inventive Principle:

Principle #40Composite materials

3Strength

If conventional crosslinking methods are used to achieve bonding strength, then adhesion is improved, but formaldehyde release occurs during the crosslinking reaction

Engineering Contradiction:

ImproveadhesionVSAvoidformaldehyde release during crosslinking

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful formaldehyde release issue into a benefit by using alternative crosslinking chemistries that not only eliminate formaldehyde but also provide equal or superior adhesion performance. The alternative monomers offer cleaner crosslinking reactions while maintaining or enhancing the bonding strength achieved by conventional methods.

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 polymer composition achieves water and solvent resistance, bonding strength comparable to N-methylol-acrylamide systems without formaldehyde release, suitable for applications like textile coating, paper coatings, and industrial finishes, with enhanced stability and safety.

Implementation Method 1

aqueous polymeric dispersions containing a triplet of functional monomers that, when submitted to heating, can crosslink, resulting in polymeric films

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Data Source

PatentEP3176187B2Formaldehyde-free thermally curable polymers

Publication Date: 2022.07.06 ORGANIK KIMYA SANAYI VE TIC AS

AI summary

The present invention relates to formaldehyde-free aqueous polymeric dispersions containing a triplet of functional monomers that, when submitted to heating, can crosslink, resulting in polymeric films without releasing formaldehyde or other hazardous materials, thus resulting in compositions with improved water and solvent resistance and bonding strength, suitable for applications such as textile coating, nonwovens, fiber bonding, paper coatings and impregnation, curable adhesives, industrial coatings and finishes and related applications. This triplet of functional monomers uses, at least, one amino- (or amido-), one epoxy- or hydroxy-, and one acid-functional monomer combination.