National Starch and Chemical Corporation

National Starch and Chemical Investment Holding Corporation

Celanese International Corporation

James L Walker

Paul R Mudge

Ronald Pangrazi

Carmine P Iovine

Pavneet Singh Mumick

David R Nass

Christopher Barcomb

Joseph G Palmer

John C Parsons

Rajeev Farwaha

Steven P Pauls, Sr

David Lunsford

Paul B Foreman

Pravin K Kukkala

Marie E Yannich

Josephine M Rosenski

Terence M Barnhart

Mourad T Mitry

Steven P Pauls Sr

A solution with a salt-sensitive polymer binder for use in fibrous webs, where the binder contains a copolymer of carboxylic acid monomer units and ethylenically unsaturated monomer units. The binder solution is prepared by emulsion-polymerizing a copolymer and then neutralizing the copolymer with base to make it water soluble. The binders provide a higher wet strength in concentrated salt solutions than in deionized water, and are particularly suitable for strengthening nonwoven fibrous webs in disposable articles such as wet-wipes, personal care products, diapers, and the like.

Method of making salt-sensitive binders and nonwoven webs

The present invention is directed to a cationic polymer emulsion binder that may be combined with a cationic active ingredient and used as a non-woven binder. This combination of cationic binder and cationic active ingredient may occur as a mixture of a cationic binder and at least one cationic active ingredient, which is then applied to loose fibers to form a non-woven; or the combination may occur after a non-woven is formed using a cationic binder, and said non-woven is then contacted with a cationic active ingredient. Non-woven wipes of the invention retain far less cationic active ingredients during use, resulting in less waste and less use of the active ingredients for the same effect as wipes made with anionic or non-ionic binders.

Crosslinkable cationic emulsion binders and their use as a binder for nonwovens

Salt-sensitive binders for nonwoven webs and method of making same

The present invention is directed to a fibrous substrate made of chemically bonded fibers, where the fibers are bound with a polymeric binder in an amount which is sufficient to bind the fibers together to form a self-sustaining web, and where the binder is characterized as having a wet tensile strength of greater than 4500 grams per inch (g/in) when measured at a 20 percent add-on on Whatman #4 CHR chromatography paper which is drum dried for 90 seconds at 210 to 215&#xb0; F. and cured for 2 minutes at 300 to 325&#xb0; F. Preferably the level of free formaldehyde in the fibrous substrate is less than 15 ppm. The emulsion binders of the invention may be used to bind fibers together in a substrate; may be used to bind pigment, colors or other substances to a substrate; may be used as a backing material; or may be used to finish or surface-treat a substrate. Because of the high level of crosslinking, substrates bound, or treated with the emulsion polymer have excellent wet strength and good durability/weatherability and water/solvent resistance.

Binder for high wet-strength substrates

A process for the production of ethylene vinyl acetate based polymer emulsions having solids levels greater than about 65% by weight comprising the steps of:

Ultra high solids vinyl acetate-ethylene and vinyl acetate homopolymer

A process for the preparation of emulsion polymers comprising 70 to 95% by weight of a vinyl ester and 5 to 30% by weight ethylene, the polymerization being carried out in the presence of 2 to 8% by weight of a protective colloid consisting of a blend of 1 to 3 percent by weight of 80% hydrolyzed polyvinyl alcohol, 0 to 2 percent by weight of 88% hydrolyzed polyvinyl alcohol and 1 to 3 percent by weight of 96% hydrolyzed polyvinyl alcohol, the blend having an average level of hydrolysis of 85 to 88%.

Ethylene-vinyl acetate emulsions with an improved balance of adhesive

A beater saturation process for forming a nonwoven wet laid composite is provided which comprises the following steps: (I) providing an aqueous dispersion comprising:

EVA polymers for use as beater saturants

The free formaldehyde content of the emulsion polymer, the amount of emitted formaldehyde and, even more particularly, of the finished nonwoven or textile may be substantially reduced by the use of a particular initiator system comprising a hydrophobic hydroperoxide and ascorbic acid. Moreover, this reduction in formaldehyde levels is accompanied by an unexpected improvement in the tensile properties of the emulsion binders.

Emulsion binders containing low residual formaldehyde and having

Latex caulk compositions comprising 30 to 80% filler and 20 to 70% by weight of an emulsion polymer prepared for the interpolymerization of 30 to 70 parts by weight of a vinyl ester of an alkanoic acid; 15 to 60 parts of an alkyl (C.sub.2 and C.sub.8) acrylate or dialkyl (C.sub.2 to C.sub.10) maleate; 10 to 30 parts ethylene; 1 to 5 parts olefinically unsaturated carboxylic acid; 0 to 5 parts polyolefinically unsaturated monomer and 0 to 8 parts of a copolymerizable functional monomer containing hydroxyl, amide or methylol substituents, (to total 100 parts by weight).

Ethylene vinyl acetate polymers for latex caulks

Formaldehyde-free heat resistant binders for flexible nonwoven products may be prepared using an emulsion polymer comprising 100 parts by weight of C.sub.1 -C.sub.4 alkyl acrylate or methacrylate or styrene/acrylate ester monomers, 0.5 to 5 parts of a hydroxyalkyl acrylate or methacrylate, 3 to 6 parts of methyl acrylamido glycolate methyl ether and 0.1 to 5 parts of a multifunctional comonomer. The binders are useful in the formation of heat resistant flexible products for use in roofing, flooring and filtering materials.

Formaldehyde-free heat resistant binders for nonwovens

Heat resistant binders for flexible nonwoven products may be prepared using an emulsion polymer comprising 100 parts by weight of C.sub.1 -C.sub.4 alkyl acrylate or methacrylate ester monomers, 0.5 to 5 parts of a hydroxyalkyl acrylate or methacrylate, 3 to 6 parts of a water soluble N-methylol containing comonomer and 0.1 to 5 parts of a multifunctional comonomer. The binders are useful in the formation of heat resistant flexible products for use in roofing, flooring and filtering materials.

Heat resistant acrylic binders for nonwovens

Laminating adhesives are described for forming flexible laminates having high bond strength, and a high degree of both humidity and water resistance. The one-part laminating adhesive compositions incorporate acrylic polymer emulsions prepared by a 'core-shell' multistage polymerization process.

Laminating adhesives

Wet laminating adhesives capable of withstanding the stresses encountered during heat sealing operations are prepared from emulsion copolymers consisting essentially of 45 to 80% by weight of a vinyl ester of an alkanoic acid, 10 to 30% ethylene, 5 to 30% of dialkyl maleate, 0.5 to 2% of an N-methylol containing comonomer and 0.5 to 4% of an ethylenically unsaturated mono- or di-carboxylic acid. These specific emulsion copolymers are prepared utilizing standard emulsion polymerization procedures with hydroxyethylcellulose or polyvinyl alcohol as a protective colloid. The emulsion polymers thus produced provide superior wet laminating adhesive properties for use in substrates which are to be formed into microwavable packages or bags.

Laminating adhesive for film/paper microwavable products

Heat resistant binders for flexible nonwoven mats may be prepared using an emulsion polymer comprising 100 parts by weight of acrylate or styrene/acrylate monomers, 3 to 6 parts of a blocked, N-methylol containing comonomer, 0 to 3 parts of a water soluble non-blocked N-methylol containing comonomer and 0 to 5 parts of a multifunctional comonomer. The use of the blocked N-methylol containing comonomer permits the incorporation into the latex binders of higher levels of N-methylol functionality with consequent increase in heat resistance. As such, the binders are useful in the formation of heat resistant flexible mats for use in roofing, flooring and filtering materials.

Growing community of inventors

Whitehouse Station, NJ, United States of America

James L Walker