Starch-Polymer Composite Binder for Heat-Stable Textile Interlinings
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Solution Overview
Problem
Textile fabrics used as base interlinings for roofing membranes lack sufficient mechanical stability, heat stability, and resistance to fire, while existing improvements increase manufacturing costs.
Innovation Solution
A binder system comprising 10-90 wt% of an aqueous dispersion of polymerizates based on conjugated aliphatic dienes and vinyl aromatic compounds, 90-10 wt% starch, and up to 10 wt% additives, which enhances heat dimensional stability and maintains flexibility and ageing characteristics without increasing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If non-woven fabrics are combined with reinforcement fibers and bonded by conglutinating or needle-punching, then mechanical stability is improved, but manufacturing costs increase
Solution Approach 1:
The patent combines synthetic non-woven fabric with natural starch binder and reinforcing fibers into a integrated composite structure. The starch binder serves dual functions as both adhesive and structural component, merging binding function with material structure to reduce overall manufacturing complexity and cost.
Solution Approach 2:
The patent modifies the binder system by using starch-based materials with specific gelatinization temperatures and molecular weights. By controlling starch parameters (amylose/amylopectin ratio, degree of substitution, gelatinization temperature), the patent achieves optimal mechanical stability at lower costs compared to conventional synthetic binders.
2Stability of the object's composition
If conventional binder systems are used to bond non-woven fabrics, then mechanical bonding is achieved, but heat dimensional stability is insufficient
Solution Approach 1:
The patent utilizes the gelatinization phase transition of starch at specific temperatures to achieve bonding. The starch undergoes phase change from crystalline to amorphous state during heating, providing temporary plasticity for bonding, then re-crystallizes upon cooling to provide heat dimensional stability. This phase transition mechanism enables the binder to maintain fabric dimensions at elevated temperatures while ensuring reliable bonding.
Solution Approach 2:
The patent creates a composite binder system combining starch with synthetic polymer components. This composite approach leverages the heat stability of synthetic polymers and the gelatinization properties of starch, achieving superior heat dimensional stability while maintaining bonding reliability through synergistic material combination.
3Ease of manufacture
If starch is used as a binder component, then cost savings are achieved, but bonding strength may be compromised
Solution Approach 1:
The patent optimizes starch parameters including molecular weight, amylose/amylopectin ratio, and degree of substitution to enhance bonding strength. By controlling these parameters, the starch binder achieves sufficient bonding strength despite being a natural, lower-cost material compared to synthetic alternatives.
Solution Approach 2:
The patent formulates a composite binder system where starch is combined with synthetic polymer components. This composite approach compensates for the inherently lower bonding strength of pure starch by incorporating reinforcing polymer elements, achieving cost savings while maintaining adequate bonding performance for the application.
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 system significantly improves heat dimensional stability and maintains flexibility and ageing characteristics, achieving cost savings by partly using starch, and results in a formaldehyde-free binder system with improved product properties.
Implementation Method 1
textile fabric solidified by means of a special binder system
Implementation Method 2
in spite of water absorption the ageing characteristics, the flexibility or stabilities have not significantly declined
Data Source
AI summary
The invention relates to a novel binder system and its use for bonding textile fabrics as well as products containing such bonded textile fabrics. The materials according to the invention are suitable for manufacturing base interlinings which may be used for manufacturing base interlinings for sarking, roofing and sealing membranes, particularly for manufacturing coated sarking, roofing and sealing membranes.