Polyester Particle Dispersion Adhesive for Recyclable Textile Bonding
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Solution Overview
Problem
Current methods for manufacturing textile products, such as floor coverings, face challenges with moisture resistance, recyclability, and durability, particularly due to the use of latex or synthetic polymer adhesives, which lead to environmental issues and limited recycling capabilities.
Innovation Solution
A dispersion of polyester particles in an aqueous medium with a number average particle size below 1000 nm and a hydrophilic-lipophilic balance (HLB) value between 7.6 and 10.5 is used as an adhesive, allowing for strong and durable bonding without the need for additional fillers or modifiers, enabling easy recycling and high-end application suitability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If latex or synthetic polymer adhesives are used to bond yarns to the primary backing, then strong bonding and durability are achieved, but moisture resistance deteriorates and recyclability is limited
Solution Approach 1:
The patent changes the chemical composition parameters of the adhesive from traditional latex or synthetic polymers to a specific polyester composition with controlled molecular weight (10,000-100,000 g/mol) and functional groups. This parameter change enables the adhesive to maintain strong bonding while gaining moisture resistance and recyclability properties.
Solution Approach 2:
The patent creates a composite adhesive system combining polyester polymer chains with specific functional groups that provide both bonding strength and moisture resistance. The composite nature of the polyester structure allows simultaneous achievement of adhesion performance and environmental resistance.
2Strength
If latex or synthetic polymer adhesives are used to bond yarns to the primary backing, then strong bonding is achieved, but recyclability deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the adhesive from traditional latex or synthetic polymers to a specific polyester composition with controlled molecular weight (10,000-100,000 g/mol) and functional groups. This parameter change enables the adhesive to maintain strong bonding while gaining moisture resistance and recyclability properties.
3Ease of manufacture
If hot melt adhesives are used to bond yarns to the primary backing, then recyclability is improved, but bonding strength and durability deteriorate
Solution Approach 1:
The patent changes the molecular weight parameters of the polyester adhesive to a specific range (10,000-100,000 g/mol) that provides optimal balance between bonding strength and recyclability. This parameter optimization enables the adhesive to achieve high tuft bind strength while maintaining ease of recycling.
Solution Approach 2:
The patent introduces specific functional groups at localized positions within the polyester polymer chains to enhance bonding strength at the yarn-adhesive interface while maintaining the overall recyclability of the adhesive system. The local functional groups provide targeted adhesion enhancement without compromising global material recyclability.
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 solution provides a textile product with high tuft bind strength and durability, suitable for high-end applications, while being easily recyclable and environmentally friendly, using commonly known equipment and processes similar to latex-based manufacturing.
Implementation Method 1
a dispersion of polyester particles in an aqueous dispersion medium
Implementation Method 2
the polyester particles are composed of a polyester material that has a HLB (hydrophilic-lipophilic balance) value between 7.6 and 10.5
Implementation Method 3
heating the thermoplastic particles on the primary backing to a temperature at or above the melting temperature of the thermoplastic particles
Implementation Method 4
heating the thermoplastic particles on the primary backing to a temperature at or above the melting temperature of the thermoplastic particles
Implementation Method 5
heating the aqueous dispersion to a temperature sufficient to remove water therefrom
Data Source
AI summary
The present invention pertains to a dispersion of polyester particles in an aqueous dispersion medium, wherein the particles have a number average particle size below 1000 nm, and wherein the polyester particles are composed of a polyester material that has a HLB (hydrophilic-lipophilic balance) value between 7.6 and 10.5.