Polymer Powder Adhesion in Dry Building Materials

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing dry building material formulations face challenges in achieving both good processing properties and strong adhesion to various substrates, particularly mineral and insulating materials like polystyrene panels, with conventional additives being costly or environmentally concerning and resulting in poorer processing properties.

Innovation Solution

Incorporating silica sols into aqueous polymer dispersions before drying to produce water-redispersible polymer powders, along with hydrolysed 1-alkylvinyl ester/vinyl ester copolymers, which enhances adhesion and processing properties by creating a synergistic effect.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional additives (phosphate esters, aromatic polyethers, polypropylene oxides) are added to improve adhesion to substrates, then adhesion strength is improved, but processing properties of fresh mortars deteriorate and cost increases

Engineering Contradiction:
Improveadhesion strengthVSAvoidprocessing properties
Core Design Contradiction:
StrengthVSEase of operation

Solution Approach 1:

The patent replaces expensive conventional additives (phosphate esters, aromatic polyethers) with a cost-effective alternative: polymer powders containing 1-alkylvinyl ester/vinyl ester copolymers and hydrolysed copolymers. These polymer powders provide the necessary adhesion improvement without the high cost and processing drawbacks of conventional additives, effectively substituting expensive materials with more economical ones that achieve the same or better performance

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention uses composite polymer powders consisting of multiple components: 1-alkylvinyl ester/vinyl ester copolymers (5-50 wt%), hydrolysed copolymers (50-95 wt%), and optionally other polymers (5-40 wt%). This composite structure combines the adhesion benefits of different polymer types while maintaining good processing properties, resolving the contradiction between adhesion strength and processing ease

Inventive Principle:
Principle #40Composite materials

2Strength

If conventional additives are added to improve adhesion to polystyrene panels, then adhesion to insulating materials is improved, but environmental concerns arise

Engineering Contradiction:
Improveadhesion to substratesVSAvoidenvironmental concerns
Core Design Contradiction:
StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent replaces environmentally concerning additives (aromatic polyethers, polypropylene oxides) with environmentally friendly polymer powders based on 1-alkylvinyl ester/vinyl ester copolymers and hydrolysed copolymers. These alternative polymers provide the required adhesion performance without the environmental hazards associated with conventional additives, eliminating harmful substances while maintaining functionality

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Stability of the object's composition

If anti-blocking agents are added to polymer powders, then storage stability is improved, but adhesion properties deteriorate

Engineering Contradiction:
Improvestorage stabilityVSAvoidadhesion properties
Core Design Contradiction:
Stability of the object's compositionVSStrength

Solution Approach 1:

The patent combines multiple functions into a single integrated polymer powder system. The polymer powders simultaneously provide: (1) storage stability through their protective colloid structure and particle morphology, (2) adhesion improvement through the specific copolymer composition, and (3) processing property enhancement. This merging of functions eliminates the need to add separate anti-blocking agents that would compromise adhesion, as the adhesion-promoting polymer structure itself provides storage stability

Inventive Principle:
Principle #5Merging (Combining)

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 approach results in improved adhesion to substrates and processing properties, particularly for lime-containing cementitious formulations, with enhanced stabilization and air retention, leading to better performance in building material compositions.

Implementation Method 1

adding silica sols to aqueous polymer dispersions and drying the resulting dispersions to form polymer powders

Methodology Applied
Scientific EffectDrying: Evaporation

Implementation Method 2

the preparation of finely divided silica microdispersions by hydrolysis of silicic esters in aqueous ammonia solution

Methodology Applied
Scientific EffectHydrolysis: Hydrolysis

Implementation Method 3

adding silica sols to the aqueous polymer dispersions... equipping dry building material formulations with polymer powders obtained by adding silica sols to aqueous polymer dispersions

Methodology Applied
Scientific EffectAdsorption: Adsorption

Data Source

PatentUS9284221B2Dry building material formulations containing polymer powders
Publication Date: 2016.03.15 WACKER CHEMIE AG

AI summary

Hydraulically setting compositions containing mineral binders exhibit improved adhesion when polymer powders produced by drying a silica sol and a redispersible polymer powder emulsion are added.