Oil-in-Water Polyester Emulsion for Uniform Glass Fiber Mats
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Solution Overview
Problem
Current binder systems for glass fibers either lack hydrolytic stability and translucency or result in non-uniform fiber mats with poor handleability, and existing polyester powdery binders have unstable dispersions leading to phase separation upon storage.
Innovation Solution
An oil-in-water emulsion using acid functional unsaturated polyester with built-in emulsifier and chain extender units, providing high hydrolytic stability, translucency, and improved binder performance, while maintaining ease of handling and uniform fiber mat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyester powdery binder is used, then hydrolytic stability and translucency are improved, but uniformity of fiber mat distribution and handleability deteriorate
Solution Approach 1:
The invention changes the physical state of the binder from powder to emulsion form, and modifies the chemical structure of the polyester by incorporating emulsifier units and chain extender units. This parameter change allows the binder to be applied as a uniform emulsion while maintaining the hydrolytic stability and translucency characteristics of polyester binders.
Solution Approach 2:
The invention creates a composite binder system by integrating multiple functional units into the polyester structure: emulsifier units (with HLB value 9-20) for water compatibility and uniform distribution, chain extender units for enhanced binding performance, and unsaturated dicarboxylic acid units for crosslinking capability. This composite structure combines the advantages of both powder and emulsion binders.
2Reliability
If polyester powdery binder is used, then hydrolytic stability and translucency are improved, but dispersion stability deteriorates due to phase separation
Solution Approach 1:
The invention changes the physical state from powder to emulsion and incorporates emulsifier units with specific HLB values (9-20) into the polyester structure. This parameter change enables stable water dispersion without phase separation, while preserving the hydrolytic stability of the polyester backbone.
Solution Approach 2:
The emulsifier units incorporated into the polyester structure act as intermediaries that provide water compatibility and stable dispersion. These units have specific HLB values (9-20) that enable the hydrophobic polyester to form stable emulsions in water without phase separation during storage.
3Ease of operation
If polyvinylacetate emulsion binder is used, then uniformity of fiber mat distribution and handleability are improved, but hydrolytic stability and translucency deteriorate
Solution Approach 1:
The invention creates a composite binder system by integrating multiple functional units into the polyester structure: emulsifier units (with HLB value 9-20) for water compatibility and uniform distribution, chain extender units for enhanced binding performance, and unsaturated dicarboxylic acid units for crosslinking capability. This composite structure combines the advantages of both powder and emulsion binders.
4Productivity
If high solid content emulsion is used, then transport and processing efficiency are improved, but water removal during drying increases
Solution Approach 1:
The invention optimizes the solid content parameter to a specific range (30-60 wt.%) that balances transport efficiency with drying requirements. This parameter optimization allows high solid content for efficient transport while limiting excessive water removal time during drying.
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 oil-in-water emulsion achieves higher hydrolytic stability and translucency compared to polyester powdery binders, with a high solid content for efficient transport and processing, and ensures a uniform, non-tacky fiber mat for enhanced resin reinforcement.
Implementation Method 1
an oil in water emulsion as binder of which the oil comprises an acid functional unsaturated polyester
Data Source
AI summary
The present invention relates to an oil-in-water emulsion, wherein the oil comprises an acid functional unsaturated polyester which acid functional unsaturated polyester comprises unsaturated dicarboxylic acid units, diol units, units of an emulsifier with HLB value of from 9 to 20 and further comprising chain extender units. The present invention further relates to a fibre mat comprising fibres and a binder comprising such acid functional unsaturated polyester.