Formaldehyde-Free Resin Dispersion Viscosity Reduction

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Solution Overview

Problem

Existing formaldehyde-free resin dispersions for mineral wool products face challenges with high viscosity, which hinders binder distribution and mechanical bonding properties, and there is a need for improved curable binder compositions that are more environmentally sustainable and economical.

Innovation Solution

A curable resin dispersion comprising water-insoluble native starch, a polycarboxylic polymer, and a non-polymeric polycarboxylic acid compound, with the polycarboxylic polymer ranging from 2 to 45 wt.-%, which provides reduced viscosity and enhanced mechanical bonding strength without compromising stability or increasing viscosity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If formaldehyde-free resin dispersions are used for mineral wool products, then environmental sustainability is improved, but viscosity increases which hinders binder distribution

Engineering Contradiction:

Improveformaldehyde emissionsVSAvoidbinder distribution

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The patent changes the chemical composition parameters of the resin by incorporating native starch (40-85 wt.%), polycarboxylic polymer (2-45 wt.%), and non-polymeric polycarboxylic acid compound (5-50 wt.%), achieving reduced viscosity while maintaining formaldehyde-free properties. This parameter optimization resolves the contradiction between environmental sustainability and ease of binder distribution.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite resin system combining three distinct components: native starch as the base polymer, polycarboxylic polymer for viscosity control, and non-polymeric polycarboxylic acid compound for crosslinking. This composite approach enables the resin to achieve low viscosity for good binder distribution while remaining formaldehyde-free for environmental sustainability.

Inventive Principle:

Principle #40Composite materials

2Strength

If polycarboxylic polymer content is increased to improve mechanical bonding, then bonding strength is improved, but viscosity increases which compromises stability

Engineering Contradiction:

Improvemechanical bonding strengthVSAvoidviscosity

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent optimizes the polycarboxylic polymer content within the specific range of 2-45 wt.% relative to total resin components. This parameter control ensures sufficient mechanical bonding strength from the polycarboxylic polymer while preventing excessive viscosity that would compromise dispersion stability. The balanced composition resolves the contradiction between bonding strength and viscosity.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If native starch is used as the base component, then cost-effectiveness and availability are improved, but solubility and dispersion stability deteriorate

Engineering Contradiction:

Improvecost-effectivenessVSAvoiddispersion stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent introduces polycarboxylic polymer and non-polymeric polycarboxylic acid compound as intermediary substances that enhance the dispersion stability of native starch. These intermediaries act as dispersants and crosslinking agents, improving the stability of the aqueous dispersion while maintaining the cost-effectiveness of native starch as the primary component (40-85 wt.%).

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention creates a composite system where native starch is combined with polycarboxylic polymer and non-polymeric polycarboxylic acid compound. This composite structure leverages the cost-effectiveness of native starch while the other components provide the necessary dispersion stability, resolving the contradiction between manufacturing cost and composition stability.

Inventive Principle:

Principle #40Composite materials

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 resin achieves reduced viscosity, improved mechanical bonding strength, and enhanced resistance to weathering influences, allowing for efficient binder distribution and improved mechanical properties of mineral wool products, while being environmentally sustainable and cost-effective.

Implementation Method 1

these hydroxyl-groups have been targeted for crosslinking reactions of starch with carboxylic groups of organic polyacids. The suitable organic polyacids can be polymeric polycarboxylic acids (especially polyacrylic acid and its derivatives) and/or low molecular weight polycarboxylic acids (e.g. citric acid)

Methodology Applied

Scientific EffectEsterification reaction: Chemical Bonding

Data Source

PatentUS10400093B2Curable formaldehyde-free resin dispersion with reduced viscosity and mineral wool products produced therewith

Publication Date: 2019.09.03 URSA INSULATION

AI summary

A curable formaldehyde-free resin in the form of an aqueous dispersion. The resin comprising components a), b) and c), wherein: a) is water-insoluble native starch, b) is a polycarboxylic polymer, and c) is non-polymeric polycarboxylic acid compound, and wherein the amount of polycarboxylic polymer (b) comprised in the resin is between 2 and 45 wt.-% relative to the sum of the weights of the components a), b) and c).