Styrene-Acrylic Binder with Crosslinkable Monomers for High Filler Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Adhesive compositions with high filler-to-binder ratios often fail to meet performance standards due to reduced bonding capabilities, particularly in industrial applications where high substrate adhesion is required.
Innovation Solution
A binder composition comprising a styrene-acrylic-based copolymer with a gel content of less than 75% and a filler-to-binder weight ratio of at least 8:1, incorporating crosslinkable monomers such as acetoacetate and epoxy functionalized (meth)acrylate monomers, along with external crosslinking agents, to enhance adhesion and shear strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high ratios of fillers to binders are used to reduce production costs, then production cost is reduced, but bonding capability is reduced and performance standards are not met
Solution Approach 1:
The patent changes the chemical composition parameters of the binder by incorporating specific functional monomers (acetoacetate monomers, epoxy functionalized (meth)acrylate monomers, and crosslinkable functional monomers) that enable crosslinking reactions. This allows the adhesive to maintain high bonding strength even at high filler-to-binder ratios (at least 5:1, preferably at least 8:1) by creating a crosslinked polymer network that provides superior adhesion and mechanical strength
Solution Approach 2:
The patent creates a composite binder system combining multiple functional components: styrene-acrylic copolymer base, crosslinkable monomers, and external crosslinking agents. This composite approach allows the adhesive to achieve both cost-effectiveness through high filler loading and high performance through the synergistic interaction of binder components that maintain bonding capability
2Quantity of substance
If gel content of styrene-acrylic copolymer is reduced to enable high filler ratios, then filler-to-binder ratio is improved, but binder performance may be compromised
Solution Approach 1:
The patent specifies that the styrene-acrylic copolymer should have a gel content of less than 75% (preferably less than 70% or less than 65%), which optimizes the balance between processability and performance. This parameter control, combined with the addition of crosslinkable monomers and external crosslinking agents, ensures that the binder maintains reliable adhesive performance while enabling high filler-to-binder ratios of at least 5:1 or at least 8:1
Solution Approach 2:
The patent introduces external crosslinking agents (amines, alkyl amine salts, diamines, polyethyleneimine, polypropyleneimine, polyamine, dihydrazide, or mixtures) as intermediaries that facilitate crosslinking reactions with the functional monomers in the binder. This mediator approach allows the system to achieve high filler loading while maintaining binder performance through the crosslinked network structure formed by these intermediary crosslinking agents
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 composition achieves improved wet shear strength and adhesion, meeting or exceeding industry standards (e.g., ANSI A 136.1) while maintaining a high filler-to-binder ratio, thus providing a cost-effective and environmentally friendly adhesive solution for various applications.
Implementation Method 1
incorporating crosslinkable monomers such as acetoacetate and epoxy functionalized (meth)acrylate monomers, along with external crosslinking agents, to enhance adhesion and shear strength
Data Source
AI summary
Styrene-acrylic-based binder compositions and methods for their preparation and use are described herein. The binder compositions include a filler and a binder comprising a styrene-acrylic-based copolymer. In some embodiments, the copolymer has a gel content of less than 75%. In some embodiments, the copolymers can be derived from at least one crosslinkable monomer. The weight ratio of filler to binder in the compositions is at least 5:1.