Aqueous binder comprising reaction products of itaconic acid
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Solution Overview
Problem
Conventional binders for fibrous insulation and non-woven mats face issues such as high formaldehyde emissions, instability, corrosion, high viscosity, and undesirable properties like low recovery and stiffness, as well as safety risks and emission problems, particularly with formaldehyde scavengers and polyacrylic acid-based binders.
Innovation Solution
An aqueous binder composition comprising a reaction product of liquid polyol monomers, itaconic acid, and C4 to C6 polyols, which provides a balance of water compatibility, low viscosity, and efficient water evaporation, reducing the need for water and inducing faster processing, while being environmentally friendly and less toxic, with a non-reversible cure mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If formaldehyde-based resins are used as binders, then binding strength is improved, but formaldehyde emissions increase causing harmful effects
Solution Approach 1:
The patent changes the chemical composition parameters of the binder by using polyacrylic acid and its derivatives instead of formaldehyde-based resins. This substitution maintains binding functionality while eliminating formaldehyde emissions, directly resolving the contradiction between binding strength and harmful emissions.
Solution Approach 2:
The patent employs polyacrylic acid and its salts as alternative binders that can be easily applied and cured without the need for formaldehyde scavengers. These binders provide sufficient binding strength for insulation products while being environmentally friendly and free from formaldehyde emission issues.
2Stability of the object's composition
If polyacrylic acid binder is used, then water compatibility is improved, but viscosity increases causing processing difficulties
Solution Approach 1:
The patent modifies the viscosity parameter by using specific derivatives and salts of polyacrylic acid, such as polyacrylamide and its derivatives, which maintain water compatibility while having lower viscosity. This allows for easier processing and application while preserving the water-based formulation advantages.
3Object-generated harmful factors
If urea is added as formaldehyde scavenger, then formaldehyde emissions are reduced, but binder stability deteriorates causing crystalline precipitates
Solution Approach 1:
The patent extracts and eliminates the need for formaldehyde scavengers entirely by using polyacrylic acid-based binders that do not release formaldehyde. This removes the source of the problem rather than attempting to mitigate it, thereby maintaining binder stability while achieving low emissions.
4Object-generated harmful factors
If ammonia is used as formaldehyde scavenger, then formaldehyde emissions are reduced, but worker safety deteriorates due to odor and irritation
Solution Approach 1:
The patent uses polyacrylic acid and its derivatives as binders that inherently do not require formaldehyde scavengers. This eliminates the need to handle ammonia or other scavenger chemicals, improving worker safety while maintaining low formaldehyde emissions.
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 composition enables faster processing, reduced water usage, improved tensile strength, and enhanced handling properties, with a high smoke point and low viscosity, making it suitable for fibrous insulation and non-woven mats, and can be used in various applications including sand molds and fiberboard construction.
Implementation Method 1
a non-reversible cure mechanism
Implementation Method 2
efficient water evaporation, reducing the need for water and inducing faster processing
Data Source
AI summary
An aqueous binder composition is provided for use in the formation of fiber insulation and non-woven mats that comprises a reaction product of one or more Liquid Polyol Monomers; itaconic acid, its salts or anhydride; and a C4 to C6 polyol selected from the group consisting of pentaerythritol, trimethylol propane, neopentyl glycol, and mixtures thereof. The molar ratio of the combined alcohols (Liquid Polyol Monomers and C4 to C6 polyols) to itaconic acid is at least 2:1, wherein the molar ratio of Liquid Polyol Monomers to C4 to C6 polyols is from about 1:1 to about 30:1.