Binder-consolidated textile fabric, method for its manufacture and its use
AssigneeJohns Manville
InventorsWerner Groh, Agnes Frick, Kiarash Alavi, Uranchimeg Lester, Ameya Natu
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Abstract
The invention concerns a novel binder system and its use for consolidating textile fabrics, as well as to products containing such consolidated textile fabrics. The materials according to the invention are suitable for the manufacture of reinforcing inserts, optionally in combination with at least one further textile fabric, for coated sarking membranes, roofing and waterproofing sheets, as textile backings or textile reinforcement in flooring, in particular in fitted carpets and PVC flooring, or in facers in wall coatings both in the interior and exterior of buildings, as well as in furniture.
Claims20
A textile fabric consolidated with a binder system comprising:
- a) 0.1 to up to 30% by weight of polymers based on polyvinyl alcohol, wherein the polyvinyl alcohol has a degree of saponification of at least 80%, and
- b) at least 70% by weight of a mixture comprising:
- (i) at least one carbohydrate;
- and
- (ii) an α-carbon nucleophile crosslinking agent that is an organic compound comprising:
- a first carbon moiety comprising an electron withdrawing group;
- and
- an α-carbon atom directly bonded to the first carbon moiety, the α-carbon atom has at least one acidic hydrogen atom and the α-carbon atom forms a nucleophile that reacts with a carbonyl carbon on the carbohydrate during polymerization of the binder system to form a cured binder, wherein the mixture has a minimum of 50% by weight of reducing sugars,
- c) a crosslinker, wherein the crosslinker is present in an amount from 0.1 wt. % to 10% by weight, said crosslinker being different from the crosslinking agent (ii) above and comprising a synthetic resin based on one or both of urea-formaldehyde and melamine-formaldehyde,
- d) 0 to 10% by weight of fillers, said fillers being different from the polymers based on polyvinyl alcohol a) above and from the mixture b) above,
- e) 0 to 10% by weight of additives,
- wherein:
- proportions by weight are based on a dry mass of the binder system, i.e., without water, and a sum of a) to e) is 100% by weight.
A method for manufacture of a textile fabric which is consolidated with a binder, comprising the steps of:
- A) forming a textile fabric;
- B) applying a binder system comprising:
- a) 0.1 to up to 30% by weight of polymers based on polyvinyl alcohol, wherein the polyvinyl alcohol has a degree of saponification of at least 80%, and
- b) at least 70% by weight of a mixture comprising:
- (i) at least one carbohydrate;
- and
- (ii) an α-carbon nucleophile crosslinking agent that is an organic compound comprising:
- a first carbon moiety comprising an electron withdrawing group;
- and
- an α-carbon atom directly bonded to the first carbon moiety, the α-carbon atom has at least one acidic hydrogen atom and the α-carbon atom forms a nucleophile that reacts with a carbonyl carbon on the carbohydrate during polymerization of the binder system to form a cured binder,
- wherein the mixture has a minimum of 50% by weight of reducing sugars,
- c) a crosslinker, wherein the crosslinker is present in an amount from 0.1 wt. % to 10% by weight, said crosslinker being different from the crosslinking agent (ii) above and comprising a synthetic resin based on one or both of urea-formaldehyde and melamine-formaldehyde,
- d) 0 to 10% by weight of fillers, said fillers being different from the polymers based on polyvinyl alcohol a) above and from the mixture b) above,
- e) 0 to 10% by weight of additives,
- wherein proportions by weight are based on a dry mass of the binder system, i.e., without water, and a sum of a) to e) is 100% by weight, by means of known methods,
- C) drying and curing the binder.
Dependencies are inferred from the claim text.