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US 7,405,169 B2Granted
Composite materials and methods of making the same
AssigneeRohm and Hass Company
InventorJin Lu
Life of this patent
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Abstract
Composite materials that contain formaldehyde-free, cured binder compositions are disclosed. Also disclosed are methods of making and using composite materials containing formaldehyde-free binder compositions.
Claims10
A composite material comprising:
- (a) a substrate material selected from fibers, slivers, chips and combinations thereof;
- and,
- (b) a cured binder composition, wherein the cured binder composition is produced from an uncured binder composition comprising a binder copolymer produced by free radical polymerization from
- (i) component A, wherein component A comprises at least one of a (meth)acrylic acid alkyl ester, styrene, and derivatives thereof;
- (ii) component B, wherein component B comprises at least one organic silane monomer according to the formula
- Rb—Si—(ORa)3
- wherein each Ra is independently selected from methyl, ethyl, propyl, isopropyl, butyl and tert-butyl;
- and, wherein Rb is selected from any substituted or unsubstituted, ethylenically unsaturated hydrocarbyl group;
- and,
- (iii) component C, wherein component C comprises at least one chain transfer agent;
- wherein the composite material comprises ≦40 wt % cured binder composition;
- with the proviso that the cured binder composition contains <1 wt % (based on solids) polymerizable unsaturated carboxylic acid monomer derived units and with the proviso that the uncured binder composition contains <0.5 wt % (based on solids) colloidal silica.
9 more elements
A method for preparing a composite material, comprising:
- (a) providing an uncured binder composition comprising a binder copolymer produced from
- (i) component A, wherein component A comprises at least one of a (meth)acrylic acid alkyl ester, styrene, and derivatives thereof;
- (ii) component B, wherein component B comprises at least one silane monomer according to the formula
- Rb—Si—(ORa)3
- wherein each Ra is independently selected from methyl, ethyl, propyl, isopropyl, butyl and tert-butyl;
- and, wherein Rb is selected from any substituted or unsubstituted, ethylenically unsaturated hydrocarbyl group;
- and
- (iii) component C, wherein component C comprises at least one chain transfer agent;
- and,
- (b) providing a substrate material selected from fibers, slivers, chips and combinations thereof;
- (c) treating the substrate material with the uncured binder composition;
- and,
- (d) curing the uncured binder composition;
- wherein the composite material comprises ≦40 wt % of the cured binder composition;
- with the proviso that the cured binder composition contains <1 wt % (based on solids) polymerizable unsaturated carboxylic acid monomer derived units and with the proviso that the uncured binder composition contains <0.5 wt % (based on solids) colloidal silica.
12 more elements
Dependencies are inferred from the claim text.