Phosphorous-acid monomer containing emulsion polymer modified urea-formaldehyde resin compositions for making fiberglass products
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Solution Overview
Problem
Aqueous urea formaldehyde (UF) resin binder compositions for fiberglass mats lack sufficient tensile strength and tear resistance, which are critical properties for applications such as asphalt coated roofing shingles, and existing emulsion polymer modified UF resin binders do not adequately address these issues.
Innovation Solution
Incorporating a multistage aqueous emulsion copolymer with a protuberant polymer stage containing phosphorous acid groups, which is copolymerized with other polymer stages to enhance mechanical properties, specifically tensile strength and tear resistance, while maintaining a measured glass transition temperature within a specific range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional UF resin binders are used for fiberglass mats, then the binder provides basic mat strength and flexibility, but the tensile strength and tear resistance are insufficient
Solution Approach 1:
The patent applies composite materials by combining UF resin with a multistage emulsion copolymer containing phosphorous acid groups. This composite binder system integrates the adhesive properties of UF resin with the mechanical strength enhancement from the specialized copolymer, achieving superior tensile strength and tear resistance while maintaining manufacturability
Solution Approach 2:
The patent employs parameter changes by modifying the binder composition to include specific proportions of phosphorous acid group-containing monomers (0.5-10 wt%) and controlling the glass transition temperature of the copolymer (-60 to 25°C). These parameter adjustments optimize the balance between strength improvement and formulation complexity
2Strength
If emulsion polymer is added to UF resin to improve flexibility, then mechanical properties such as tensile strength and tear resistance increase, but the binder composition complexity increases
Solution Approach 1:
The patent applies local quality by creating a multistage emulsion copolymer with distinct functional regions: a first polymer stage containing phosphorous acid groups for adhesion, and a second polymer stage with different Tg for flexibility. This localized functional differentiation within the copolymer structure provides enhanced mechanical properties while managing composition complexity
Solution Approach 2:
The patent uses segmentation by dividing the emulsion copolymer into multiple polymer stages with distinct functions. The first stage (phosphorous acid-containing) and second stage (different Tg) are segmented to provide both adhesion and flexibility, allowing the binder to achieve superior mechanical properties without excessive overall complexity
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 use of a multistage emulsion copolymer with a protuberant phosphorous acid group containing polymer stage significantly improves the tensile strength and tear resistance of fiberglass mats, outperforming conventional UF resin binders, and demonstrates utility in high-stress applications like asphalt coated roofing shingles.
Implementation Method 1
aqueous urea formaldehyde (UF) resin binder compositions comprising at least one multistage emulsion copolymer as a polymer modifier wherein one polymer stage of the multistage emulsion copolymer comprises at least one phosphorous acid group containing polymer
Implementation Method 2
The binder compositions impart mat strength to the ultimately cured mat, and function to improve the strength of the uncured, wet-laid mat
Data Source
AI summary
The present invention provides polymer modified aqueous urea formaldehyde resin (UF resin) binder compositions useful in making a treated glass mat, e.g., for roofing shingles, wherein the polymer modifier is an multistage aqueous emulsion acorn copolymer comprising one protuberant polymer stage containing phosphorous acid groups and one or more other polymer stage comprising an addition copolymer incompatible with the protuberant polymer stage, wherein the multistage aqueous emulsion copolymer has a measured Tg of from −60 to 25° C., or, preferably from −30 to 12° C. and, further wherein the weight ratio of the total of monomers used to make the one or more other polymer stage to the total amount of monomers used to make the protuberant polymer stage ranges from 3:1 to 50:1, or, preferably, from 3:1 to 30:1 or, more preferably, from 3:1 to 20:1, or, even more preferably, from 8:1 to 12:1.