Polyester Binder Composition for Formaldehyde-Free Nonwoven Strength
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Solution Overview
Problem
Existing nonwoven substrates face challenges in achieving good mechanical properties, particularly wet tensile strength, while avoiding formaldehyde release and incorporating bio-sourced components, especially in applications like personal care and food products.
Innovation Solution
A polyester resin is used as a binder for chemically bonding nonwoven fibers, comprising a polyol, polyacid, fatty, and rosin components, providing a bio-sourced and optionally biodegradable solution with good water absorbency and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If acrylic binders are used for chemically bonding nonwoven fibers, then good mechanical properties are achieved, but formaldehyde release occurs and bio-sourced content is low
Solution Approach 1:
The invention changes the chemical composition parameters of the binder by using polyester resin with specific polyol and polyacid components instead of traditional acrylic binders, thereby eliminating formaldehyde release while maintaining mechanical bonding properties
Solution Approach 2:
The invention creates a composite binder system combining polyester resin with specific polyol components (glycerol, pentaerythritol) and polyacid components (fatty acids, rosin) to achieve both mechanical strength and formaldehyde-free properties
2Strength
If polyester resin with polyol and polyacid components is used as binder, then wet tensile strength is improved and formaldehyde release is eliminated, but bio-sourced content needs to be increased
Solution Approach 1:
The invention modifies the binder composition by incorporating bio-sourced polyol components (glycerol, pentaerythritol) and polyacid components (fatty acids from vegetable oils, rosin) to increase bio-sourced content while maintaining wet tensile strength
Solution Approach 2:
The invention replicates the functional properties of petroleum-based acrylic binders using bio-sourced polyester resin components, achieving similar mechanical performance with renewable materials
3Ease of manufacture
If traditional binders are used, then manufacturing process is simple, but environmental concerns arise due to formaldehyde content
Solution Approach 1:
The invention changes the chemical parameters of the binder from formaldehyde-containing acrylic resins to formaldehyde-free polyester resins, eliminating environmental hazards while maintaining manufacturing process simplicity through direct application and curing
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 polyester resin binder achieves nonwoven substrates with enhanced wet tensile strength, bio-sourced content, and absence of formaldehyde, addressing the mechanical and environmental concerns of traditional binders.
Implementation Method 1
Chemical bonding is a consolidation method involving the use of an aqueous dispersion of polymer particles (also referred to as a latex) to bond the fibers
Implementation Method 2
curing the binder, thereby bonding the nonwoven fibers together to form a chemically bonded nonwoven substrate
Data Source
AI summary
The present invention relates to chemically bonded nonwoven substrates and to polyester binders for chemically bonding nonwoven fibers of a nonwoven substrate.