Curable aqueous composition
View Patent ↗A curable aqueous composition that includes a first polymer that includes carboxyl groups, and a second component that includes a second water insoluble polymer and a stabilizer. The second component includes functional groups that react with the carboxyl groups of the first polymer during cure, is free from carboxylic acid groups, or a combination thereof. The composition, when dry, exhibits a first Tg of at least 10° C. and a second Tg of at least 50° C.
1. An aqueous binder composition comprising:
at least about 15% by weight, based on solids, of a water soluble, carboxy functional, hydroxy functional solution polymer; and
a component comprising
a water insoluble polymer derived from vinyl acetate, the water insoluble polymer exhibiting a glass transition temperature of at least 10° C. and
a stabilizer,
at least one of the water insoluble polymer and the stabilizer comprising functional groups that react with the carboxyl groups of the solution polymer during crosslinking,
the binder composition, when dry, exhibiting a first glass transition temperature of at least 10° C. and a second glass transition temperature of at least 50° C.
2. An aqueous binder composition comprising:
at least about 15% by weight, based on solids, of a water soluble, carboxy functional, hydroxy functional solution polymer comprising carboxyl groups and hydroxyl groups; and
a component comprising a water insoluble polymer that exhibits a glass transition temperature of at least 10° C., and a stabilizer, the water insoluble polymer being free of carboxylic acid groups,
the binder composition, when dry, exhibiting a first glass transition temperature of at least 20° C. and a second glass transition temperature of at least 50° C.
3. The binder composition of claim 1 , wherein the ratio of the weight of the water insoluble polymer and stabilizer to the weight of the solution polymer is from about 85:15 to about 20:80.
4. The binder composition of claim 1 , wherein the ratio of the weight of the water insoluble polymer and stabilizer to the weight of the solution polymer is from about 85:15 to about 45:55.
5. The binder composition of claim 1 , wherein the cured binder composition exhibits a hardness of at least 6.
6. The binder composition of claim 1 , wherein the cured binder composition exhibits a hardness of at least 7.
7. The binder composition of claim 1 , wherein the cured binder composition exhibits a hardness of at least 8.
8. The binder composition of claim 1 , wherein the water insoluble polymer is derived from ethylenically unsaturated monomer.
9. The binder composition of claim 1 , wherein the water insoluble polymer comprises at least one of polyvinyl acetate and vinyl acetate copolymer.
10. The binder composition of claim 1 , wherein the stabilizer comprises starch.
11. The binder composition of claim 1 , wherein the water insoluble polymer is derived from at least one of vinyl acetate, acrylate, styrene, olefin, and acrylamide.
12. The binder composition of claim 1 , wherein the water insoluble polymer is an emulsion polymer.
13. The binder composition of claim 1 , wherein the component is an emulsion.
14. The binder composition of claim 1 , wherein the stabilizer comprises a protective colloid.
15. The binder composition of claim 1 , wherein the stabilizer comprises at least one of starch, hydroxymethyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, polyvinyl alcohol, and surfactant.
16. The binder composition of claim 1 , wherein the stabilizer comprises surfactant and the surfactant comprises functional groups that are reactive with the first polymer.
17. The binder composition of claim 1 , wherein the water insoluble polymer comprises hydroxyl groups.
18. The binder composition of claim 1 further comprising at least one of a polyol, an alkanolamine, a silane, and a wax dispersion.
19. The binder composition of claim 1 further comprising a latent acid catalyst.
20. The binder composition of claim 1 further comprising a latent acid catalyst comprising ammonium nitrate.
21. An aqueous binder composition comprising:
a solution comprising a first carboxy functional, hydroxy functional polymer comprising carboxyl groups and hydroxyl groups;
at least about 15% by weight, based on solids, of the first polymer; and
an emulsion comprising
a second water insoluble polymer derived from vinyl acetate, the water insoluble polymer exhibiting a glass transition temperature of at least 10° C., and
a stabilizer,
at least one of the water insoluble polymer and the stabilizer comprising a functional group that is reactive with the carboxyl groups of the first polymer during crosslinking,
the binder composition, when dry, exhibiting a first glass transition temperature of at least 10° C. and a second glass transition temperature of at least 50° C.
22. The binder composition of claim 2 , wherein the first glass transition temperature is at least 25° C.
23. The binder composition of claim 1 , wherein the first glass transition temperature is no greater than 60° C.
24. The binder composition of claim 1 , wherein the first glass transition temperature is no greater than 55° C.
25. The binder composition of claim 1 , wherein the first glass transition temperature is no greater than 40° C.
26. An aqueous binder composition comprising:
a carboxy functional, hydroxyl functional solution polymer; and
a component comprising
a water insoluble polymer derived from vinyl acetate, and
a stabilizer,
at least one of the water insoluble polymer and the stabilizer comprising functional groups that react with the carboxyl groups of the carboxy functional, hydroxyl functional solution polymer during crosslinking,
the binder composition, when dry, exhibiting a first glass transition temperature of at least 10° C. and a second glass transition temperature of at least 50° C.
27. An aqueous binder composition comprising:
a water soluble, carboxy functional, hydroxy functional solution polymer comprising carboxyl groups and hydroxyl groups; and
a component comprising
a water insoluble polymer derived from vinyl acetate and comprising hydroxyl groups, the water insoluble polymer exhibiting a glass transition temperature of at least 10° C., and
a stabilizer,
the binder composition, when dry, exhibiting a first glass transition temperature of at least 10° C. and a second glass transition temperature of at least 50° C.
28. An aqueous binder composition comprising:
a first polymer comprising carboxyl groups and hydroxyl groups;
a component comprising
a water insoluble polymer derived from vinyl acetate and exhibiting a glass transition temperature of at least 10° C., and
a stabilizer,
at least one of the water insoluble polymer and the stabilizer comprising functional groups that react with the carboxyl groups of the first polymer during crosslinking; and
a latent acid catalyst,
the binder composition, when dry, exhibiting a first glass transition temperature of at least 10° C. and a second glass transition temperature of at least 50° C.
29. The binder composition of claim 28 , wherein the latent acid catalyst comprises ammonium nitrate.
30. The binder composition of claim 1 , wherein the water insoluble polymer exhibits a glass transition temperature of at least 25° C.
31. A method of using the binder of claim 1 , said method comprising contacting a substrate with the binder composition.
32. The method of claim 31 , wherein the substrate comprises at least one of fibers and particles.