Thermosetting Binder from Reducing Sugars and Polyamines
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Solution Overview
Problem
Existing formaldehyde-free binders for fibrous building materials lack durability, water resistance, and suitable tensile strength, particularly for flexible substrates, and often require harsh curing conditions, which limits their practical application.
Innovation Solution
Aqueous binder compositions comprising diprimary diamines, poly(primary amines), and reducing sugars, along with capping agents, vinyl emulsion polymers, and reactive waterproofing agents, which are free from strong acids and polycarboxylic acids, to create a thermosetting binder that cures rapidly and provides improved tensile strength and water resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If formaldehyde-free binders are made from sustainable materials (proteins or amino acids with reducing sugars), then environmental sustainability is improved, but tensile strength and water resistance are insufficient
Solution Approach 1:
The patent modifies the chemical parameters of the binder system by introducing specific amino acid derivatives (amino-modified polysaccharides, amino-proteins, amino-starches) and controlling their molecular weight and functional group content. This enables the binder to achieve both formaldehyde-free composition and adequate tensile strength through optimized chemical structure and composition ratios.
Solution Approach 2:
The patent creates composite binder systems combining multiple components: amino-modified polysaccharides/proteins/starches with specific functional groups, along with crosslinking agents and fillers. This composite approach allows the binder to achieve both environmental sustainability and mechanical strength through synergistic material interactions.
2Object-generated harmful factors
If formaldehyde-free binders are made from proteins or amino acids with reducing sugars, then environmental sustainability is improved, but water resistance is insufficient
Solution Approach 1:
The patent modifies the chemical parameters by introducing amino groups with specific functionality and controlling the molecular weight and crosslinking density of the binder system. This enables the formation of water-resistant crosslinked networks while maintaining formaldehyde-free composition through optimized chemical structure and composition ratios.
Solution Approach 2:
The patent creates composite binder systems combining amino-modified polysaccharides/proteins/starches with crosslinking agents and water-resistant fillers. This composite approach allows the binder to achieve both environmental sustainability and water resistance through synergistic material interactions and crosslinked network formation.
3Object-generated harmful factors
If existing formaldehyde-free binders are used, then formaldehyde content is reduced, but curing conditions become harsh
Solution Approach 1:
The patent modifies the curing chemistry by using amino group-based crosslinking mechanisms that proceed at lower temperatures compared to traditional formaldehyde-based systems. The amino-functionalized polymers enable moderate-temperature curing through controlled crosslinking reactions, eliminating the need for harsh high-temperature processing while maintaining formaldehyde-free composition.
4Object-generated harmful factors
If formaldehyde-free binders are made from proteins or amino acids with reducing sugars, then environmental sustainability is improved, but tensile strength is insufficient for flexible substrates
Solution Approach 1:
The patent modifies the binder chemistry by introducing amino groups with specific functionality and controlling molecular weight and crosslinking density to achieve adequate tensile strength while maintaining flexibility. The amino-functionalized polymers with optimized composition and crosslinking enable the binder to meet mechanical performance requirements for flexible substrates without relying on formaldehyde-based systems.
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 binder compositions exhibit enhanced hot wet tensile strength, durability, and rapid development of physical properties during curing, reducing cure energy and minimizing formaldehyde content, making them suitable for a wide range of substrates including flexible materials.
Implementation Method 1
form melanoidins from the condensation of proteins or amino acids with reducing sugars as thermosets
Implementation Method 2
cure only in very harsh conditions and provide cured products with inadequate tensile strength
Data Source
AI summary
The present invention provides thermosetting aqueous binder compositions of one or more diprimary diamine, e.g. lysine, or poly(primary amine), e.g. polyethylenimine, and one or more reducing sugar in which the number of equivalents of primary amine relative to the number of equivalents of carbonyl groups in the reducing sugar ranges from 0.4:1 to 2:1, the binders being suitable for use on fiber, nonwoven, woven web and finely divided substrates. The binders are at least substantially formaldehyde free, need no polycarboxylic or polycarboxylate component, and yet provide excellent hot wet tensile strength when cured for as little time as a minute or less in use.