High strength polyvinyl acetate binders
OwnerDavid Lunsford, Cindy Dressendofer +2inventors
InventorsDavid Lunsford, Cindy Dressendofer, Rajeev Farwaha, Phillip Davis
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Abstract
A binder composition for fibrous substrates that includes a low-pressure polymerized emulsion resin comprising vinyl acetate monomer units and post-crosslinking monomer composition. The inventive compositions enable fibrous substrates with high tensile strengths and excellent curability, and are particularly useful as binders in synthetic fiberfill applications.
Claims47
An emulsion binder composition for fibrous substrates, wherein the binder composition includes:
- i) water;
- and
- ii) an emulsion resin which comprises from 50 pphwm to 100 pphwm vinyl acetate monomer units and from 4 to 15 pphwm post-crosslinking monomer composition, where the emulsion resin is polymerized at a pressure of less than 250 psi, and
- wherein the binder composition provides a characteristic dry cross-machine direction tensile strength of at least about 10,000 gf/in (CMD test).
Fiberfill comprising synthetic fibers and an emulsion binder, wherein said emulsion binder includes a polymer having from 90 to 100 pphwm vinyl acetate and from 4 to 15 pphwm of post-crosslinking monomer composition, and wherein the emulsion binder exhibits an air-dried insolubles level of at least 45 percent.
In a method of making an aqueous emulsion binder by emulsion polymerizing a reaction mixture in a reaction vessel, the improvement comprising:
- i) polymerizing the reaction mixture at approximately atmospheric pressure and a reaction temperature, wherein the mixture includes (A) 50-100 pphwm vinyl acetate, (B) 4-15 pphwm post-crosslinking monomer, and (C) a redox initiating system;
- ii) concurrently slow-adding components (A), (B), and (C) to the reaction vessel;
- and
- iii) controlling the amounts and addition rates of (A), (B), and (C) and controlling the reaction temperature, such that the binder composition exhibits an air-dried insolubles level of at least 45 percent.
Dependencies are inferred from the claim text.