Aqueous composition comprising multi-stage latex polymer particles
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Solution Overview
Problem
Formaldehyde-free latex polymers for textiles face challenges in achieving sufficient mechanical properties and retaining tensile strength when exposed to water or solvents, due to the limitations of external crosslinking agents which are difficult to impregnate and have a limited pot life.
Innovation Solution
An aqueous composition containing multi-stage latex polymer particles, comprising a first-stage polymer with an ethylenically unsaturated acid monomer and a vinyl monomer, and a second-stage polymer with an ethylenically unsaturated monomer and an epoxy group, which are bound together to provide improved crosslinking without the need for external agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If external crosslinking agents are used to improve mechanical properties of formaldehyde-free latex polymers, then tensile strength is improved, but impregnation difficulty increases and pot life decreases
Solution Approach 1:
The patent combines the crosslinking functionality directly into the latex polymer structure by incorporating epoxy groups during polymerization. This merging eliminates the need for separate external crosslinking agents, allowing the polymer to self-crosslink upon contact with moisture from the textile or environment, thereby improving both impregnation ease and maintaining adequate pot life while achieving sufficient mechanical properties
Solution Approach 2:
The latex polymer is designed to be self-crosslinking through its inherent epoxy groups that react with moisture. This self-service mechanism eliminates dependency on external crosslinking agents, enabling the polymer to develop its mechanical properties autonomously after application to the textile, thus resolving the impregnation and pot life issues associated with external agents
2Strength
If external crosslinking agents are used to achieve sufficient mechanical properties, then tensile strength retention is improved, but the article's tensile strength retention after water exposure deteriorates
Solution Approach 1:
The patent changes the chemical parameters of the crosslinking mechanism by using epoxy groups that undergo moisture-curing reactions. This parameter change allows crosslinking to occur gradually upon exposure to moisture from the textile or environment, creating a more stable and water-resistant crosslinked structure that maintains tensile strength retention after water exposure, unlike traditional external crosslinking agents
3Strength
If external crosslinking agents are used to improve mechanical properties, then initial strength is improved, but the composition's stability and pot life deteriorate
Solution Approach 1:
The epoxy groups are incorporated into the latex polymer structure during the polymerization process, preparing the polymer in advance with latent crosslinking capability. This preliminary action allows the polymer to remain stable during storage and application (maintaining pot life) while being ready to crosslink automatically when exposed to moisture, thus resolving the contradiction between initial strength development and composition stability
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 multi-stage latex polymer particles enhance the retention of tensile strength in textiles even when exposed to water or solvents, offering a stable and effective binding solution without the use of formaldehyde or external crosslinking agents.
Implementation Method 1
a second-stage polymer containing (i) an ethylenically unsaturated monomer with an epoxy group and (ii) a second vinyl monomer
Data Source
AI summary
An aqueous composition including multi-stage latex polymer particles is provided. The multi-stage latex polymer particles include (A) a first-stage polymer containing (i) an ethylenically unsaturated acid monomer with two carboxylic acid groups and (ii) a first vinyl monomer, and (B) a second-stage polymer containing (i) an ethylenically unsaturated monomer with an epoxy group and (ii) a second vinyl monomer. An article including a nonwoven textile impregnated with the aqueous composition is also provided.