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US 9,309,351 B2Granted
Styrene-acrylic-based binders and methods of preparing and using same
AssigneeBASF SE
InventorKostas S. Avramidis
Life of this patent
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Abstract
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.
Claims29
A binder composition, comprising:
- an inorganic filler, wherein the inorganic filler is selected from the group consisting of calcium carbonate, ground/recycled glass, milled glass, glass spheres, glass flakes, clays, feldspar, mica, talc, activated carbon, metals, alloys, metal-plated particulates, sol-gel ceramics, precipitated ceramics, fused silica, fumed silica, amorphous fused silica, aluminum trihydrate, sand, ground sand, slate dust, crusher fines, red mud, amorphous carbon, wollastonite, alumina, bentonite, quartz, garnet, saponite, beidellite, granite, calcium oxide, calcium hydroxide, antimony trioxide, barium sulfate, magnesium oxide, titanium dioxide, zinc carbonate, zinc oxide, nepheline syenite, perlite, diatomite, pyrophillite, soda ash, trona, inorganic fibers, and mixtures thereof;
- a binder comprising a styrene-acrylic-based copolymer derived from styrene and a (meth)acrylate, said styrene-acrylic-based copolymer having a gel content of greater than 40% to less than 75%;
- and
- a nonionic surfactant in an amount of about 9% or greater by weight, based on the total weight of the styrene-acrylic-based copolymer,
- wherein the weight ratio of the inorganic filler to binder is at least 12:1.
2 more elements
A binder composition, comprising:
- an inorganic filler;
- and
- a binder comprising a styrene-acrylic-based copolymer derived from styrene and a (meth)acrylate;
- and
- a nonionic surfactant in an amount of about 9% or greater by weight, based on the total weight of the styrene-acrylic-based copolymer,
- wherein the weight ratio of the inorganic filler to binder is at least 5:1, and
- wherein the gel content of the styrene-acrylic-based copolymer is greater than 40% to less than 75%.
4 more elements
A method of preparing a binder composition, comprising:
- co-polymerizing styrene and a (meth)acrylate to form a binder comprising a styrene-acrylic-based copolymer;
- and
- mixing the binder with an inorganic filler to provide at least a 5:1 weight ratio of the inorganic filler to binder and a nonionic surfactant in an amount of about 9% or greater by weight, based on the total weight of the styrene-acrylic-based copolymer,
- wherein the styrene-acrylic-based copolymer has a gel content of greater than 40% to less than 75%.
1 more element
A method of preparing a binder composition, comprising:
- co-polymerizing styrene and a (meth)acrylate to form a binder comprising a styrene-acrylic-based copolymer, wherein said styrene-acrylic-based copolymer has a gel content of greater than 40% to less than 75%;
- and
- mixing the binder with an inorganic filler to provide at least a 12:1 weight ratio of the inorganic filler to binder and a nonionic surfactant in an amount of about 9% or greater by weight, based on the total weight of the styrene-acrylic-based copolymer,
- wherein the inorganic filler is selected from the group consisting of calcium carbonate, ground/recycled glass, milled glass, glass spheres, glass flakes, clays, feldspar, mica, talc, activated carbon, metals, alloys, metal-plated particulates, sol-gel ceramics, precipitated ceramics, fused silica, fumed silica, amorphous fused silica, aluminum trihydrate, sand, ground sand, slate dust, crusher fines, red mud, amorphous carbon, wollastonite, alumina, bentonite, quartz, garnet, saponite, beidellite, granite, calcium oxide, calcium hydroxide, antimony trioxide, barium sulfate, magnesium oxide, titanium dioxide, zinc carbonate, zinc oxide, nepheline syenite, perlite, diatomite, pyrophillite, soda ash, trona, inorganic fibers, and mixtures thereof.
1 more element
A method of adhering a substrate to a surface, comprising the steps of:
- (1) applying to a surface or to a substrate a binder composition, comprising water, an inorganic filler, a binder comprising a styrene-acrylic-based copolymer, and a nonionic surfactant in an amount of about 9% or greater by weight, based on the total weight of the styrene-acrylic-based copolymer, wherein the weight ratio of the inorganic filler to binder is at least 12:1, the styrene-acrylic-based copolymer has a gel content of greater than 40% to less than 75%, and the inorganic filler is selected from the group consisting of calcium carbonate, ground/recycled glass, milled glass, glass spheres, glass flakes, clays, feldspar, mica, talc, activated carbon, metals, alloys, metal-plated particulates, sol-gel ceramics, precipitated ceramics, fused silica, fumed silica, amorphous fused silica, aluminum trihydrate, sand, ground sand, slate dust, crusher fines, red mud, amorphous carbon, wollastonite, alumina, bentonite, quartz, garnet, saponite, beidellite, granite, calcium oxide, calcium hydroxide, antimony trioxide, barium sulfate, magnesium oxide, titanium dioxide, zinc carbonate, zinc oxide, nepheline syenite, perlite, diatomite, pyrophillite, soda ash, trona, inorganic fibers, and mixtures thereof;
- (2) contacting the surface and the substrate along the binder composition;
- and
- (3) removing water from the binder composition.
1 more element
Dependencies are inferred from the claim text.