Starch-Based Latex Replacement With Stable Viscosity for Carpet Backing
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Solution Overview
Problem
Current methods fail to provide a satisfactory replacement for synthetic latex polymers with starch-based compositions, particularly in applications like carpet-backing, sizing, and coating, due to issues with viscosity, stability, and adhesiveness, and the difficulty in achieving uniform gelatinization and swelling of starch particles.
Innovation Solution
A process involving the use of cold water-soluble starch derivatives, stabilization with unsaturated organic compounds, neutralization, and functionalization to create a starch-based composition that can replace latex, offering stable viscosity and high wet strength, and can be used in hybrid binder compositions with latex.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If starch is used to replace synthetic latex polymers, then environmental friendliness is improved, but viscosity control and stability are worsened
Solution Approach 1:
The starch is pre-gelatinized before use in the composition. This preliminary gelatinization treatment modifies the starch structure in advance, allowing it to maintain stable viscosity when mixed with aqueous latex and fillers, thereby resolving the viscosity control issue while preserving environmental benefits
Solution Approach 2:
The patent changes the physical-chemical parameters of starch through gelatinization and controlled fragmentation. This transforms the starch from a raw state to a modified state with improved flow properties and viscosity stability, enabling it to function effectively as a latex replacement without excessive thickening
2Stability of the object's composition
If starch is pre-gelatinized to reduce viscosity, then viscosity control is improved, but granular character is worsened
Solution Approach 1:
The starch undergoes partial gelatinization rather than complete gelatinization. This controlled partial treatment achieves sufficient viscosity reduction while preserving enough granular structure to maintain the desired physical properties of the composition
Solution Approach 2:
The gelatinization process is controlled to affect only the outer layers of starch granules while preserving the core granular structure. This creates a gradient structure where the surface is modified for flow properties but the interior maintains granular character
3Ease of manufacture
If starch gelatinization is performed in situ during drying, then process simplicity is improved, but uniform swelling is worsened
Solution Approach 1:
Gelatinization is performed as a preliminary step before the drying process rather than during drying. This preliminary gelatinization ensures uniform swelling of starch particles occurs under controlled conditions, avoiding the non-uniform swelling that would result from in-situ gelatinization during drying
Solution Approach 2:
The manufacturing process is divided into distinct sequential steps: gelatinization first, then drying. This segmentation allows each process to be optimized independently, ensuring uniform starch swelling is achieved before the drying phase begins
4Shape
If swelling inhibitor such as urea is added to retain granular structure, then granular structure retention is improved, but adhesiveness is worsened
Solution Approach 1:
The harmful effect of swelling inhibitors on adhesiveness is eliminated by removing this step from the process. Instead of adding urea or similar inhibitors, the patent uses controlled gelatinization methods that retain granular structure through physical modification rather than chemical inhibition, thereby preserving adhesiveness
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 resulting starch-based composition provides stable viscosity over time, maintains high wet strength, and can replace latex in various applications, including carpet backing, with reduced volatile organic compound emissions and improved sustainability.
Implementation Method 1
reacting the starch and/or starch derivative with a stabilising agent
Implementation Method 2
The present invention provides stable viscosity over time
Data Source
AI summary
A method for producing starch-based compositions, and the composition produced therewith, for use as latex substitutes for full or partial latex replacement in applications such as carpet backing.