Fast curing binder for cellulose

Abstract: Non-formaldehyde emitting binders for nonwoven cellulosic materials comprise a solution copolymer of an olefinically unsaturated organic compound having at least one carboxylate group, which is reacted with a primary or secondary amide of an olefinically unsaturated carboxylic acid. The product of said reaction is admixed with a non-formaldehyde containing latex carrier which has been formulated with a non-formaldehyde forming reactive monomer to produce binder compositions which reach substantially fully cured wet strength in 8 seconds or less.

Description: The invention relates to polymeric binders for cellulose and more particularly to fast curing compositions based on a solution polymerized copolymer system admixed with a polymeric carrier latex which is especially useful where low formaldehyde emitting applications are involved. BACKGROUND OF THE INVENTION During the past few years there has been a substantial growth in the production of high-strength paper and cloth products having a nonwoven, randomly-oriented structure, bonded with a polymeric resin binder. Such products are finding wide use as high-strength, high-absorbency materials for disposable items such as consumer and industrial wipes/towels, diapers, surgical packs and gowns, industrial work clothing and feminine hygiene products. They are also used for durable products such as carpet and rug backings, apparel inter-linings, automotive components and home furnishings, and for civil engineering materials such as road underlays. There are several ways to apply such a binder to these materials, including spraying, print binding, and foam application. Further, depending on the end use, various ingredients such as catalysts, cross-linkers, surfactants, thickeners, dyes, and flame retardant salts may also be incorporated into the binder system. In the high-speed, high-volume manufacture of cellulosic products such as wet wipes, an important binder property is a fast cure rate; i.e., the finished product must reach substantially full tensile strength in a very short time after binder application so that production rates are not unduly slowed down. In these products, such a property is usually obtained by using a binder which is either self cross-linkable or by incorporating an external cross-linker into the binder formulation. When this is done, the cross-linker apparently not only interacts with the binder monomers but with the hydroxyl groups on the cellulose fibers to quickly form very strong bonds. At present, there are a number of available binder formulations which meet this requirement. However, these materials are typified by incorporating one or more constituents which, over some period of time, will emit formaldehyde in amounts which may be sufficient to cause skin and respiratory irritation in may people, particularly in children. Most recently, several of the leading manufacturers of nonwoven cellulosic products have expressed a desire to replace such binders with products offering equivalent levels of performance in cellulose but without the emission of formaldehyde. Although a number of ostensibly zero formaldehyde or "0 CH₂O" cellulose binders have been proposed, they have either not been truly "0" in formaldehyde content or have not shown sufficiently fast cure rates to be acceptable in high-volume production applications. EP-A-0 084 809 discloses the preparation of formaldehyde-free and nitrile-free latexes for use as nonwoven binders. These latexes are acrylic or styrene acrylic latexes made with functional monomers that include hydroxyalkylacrylates, amides, and difunctional monomers such as ALMA. Copolymerized carboxylic acids, both mono- and di-functional, as well as other monomer that do not contain or generate formaldehyde, or contain nitrile groups are optional. The binder is a single polymeric substance, that is, the monomers are copolymerized in one reaction to form one basic backbone. EP-A-0 184 153 discloses a similar polymeric binder. In accordance with the present invention there is provided a fast-curing binder for nonwoven cellulosic materials, said binder comprising a solution copolymer formed by the reaction of a first water-soluble comonomer comprised of one or more olefinically unsaturated compounds having at least one carboxylate group, said compounds having the general formula: wherein R₁, R₂ and R₃ are independently selected from hydrogen, halogen, nitro, amino and organic radicals; and R₄ is hydrogen or an organic radical; and X is an organic radical or a covalent bond, with a second water-soluble comonomer comprised of one or more amides of olefinically unsaturated carboxylic acids, said amides having the general formula: wherein R₅, R₆ and R₇ are independently selected from hydrogen, halogen, nitro, amino and organic radicals; R₈ and R₉ are hydrogen or organic radicals; and Y is an organic radical or a covalent bond, with said solution copolymer being admixed in an amount between 2% to 20%, by weight, with a non-formaldehyde emitting latex carrier formulated with between 2% and 15%, by weight, of a substantially non-formaldehyde forming reactive monomer selected from methylacryloamido glycolatemethyl ether and isobutoxymethyl acrylamide to produce said binder. The present invention comprises a fast-curing, zero formaldehyde binder composition for nonwoven cellulosic materials. The binder comprises a polymeric composition formed by the solution copolymerization of a mixture containing at least two water-soluble monomers. The first of these water-soluble comonomers comprises one or more organic compounds having at least one olefinically unsaturated linkage with at least one carboxylate group, said compounds having the general formula: wherein R₁, R₂, and R₃ are independently hydrogen, halogen, nitro, amino, and organic groups; R₄ is hydrogen or an organic radical, usually containing no more than 10 carbon atoms; and X is a covalent bond or an organic radical, usually of no more than 10 carbon atoms. Normally, the number of all the carbon atoms in compound (a) is no greater than 30. This first comonomer is reacted with a second water-soluble comonomer comprised of one or more compounds having the general formula: wherein R₅, R₆, and R₇ are independently selected from nitro, hydrogen, halogen, amino, and organic radicals; R₈ and R₉ are hydrogen or organic radicals, preferably having no more than 6 carbon atoms; and Y is a covalent bond or an organic radical, usually of no more than about 10 carbon atoms. In a second embodiment of this invention, the solution polymer further comprises one or more third water-soluble compounds having the general formula: wherein R₁₀, R₁₁, and R₁₂ are independently selected from hydrogen, halogen, nitro, amino, and organic radicals, usually of no more than 10 carbon atoms; R₁₃ is an organic radical having at least 2, and usually no more than 10, carbon atoms, with at least one of R₁₀, R₁₁, R₁₂, and R₁₃ being an organic radical having a hydroxyl substituent thereon, said hydroxyl substituent being at least 2 carbon atoms away from the carboxylate group. Where one or more of R₁₀, R₁₁, and R₁₂ are organic radicals having a hydroxyl substituent, R₁₃ is preferably an unsubstituted hydrocarbyl radical, usually of no more than 10 carbon atoms. Z is a covalent bond or an organic radical, usually of no more than 10 carbon atoms. The term "organic" radical, when used herein, broadly refers to any carbon-containing radical. Such radicals may be cyclic or acyclic, may have straight or branched chains, and can contain one or more hetero atoms such as sulfur, nitrogen, oxygen and phosphorus. Further, they may be substituted with one or more substituents such as thio, hydroxy, nitro, amino, nitrile, carboxyl and halogen. In addition to aliphatic chains, such radicals may contain aryl groups, including arylalkyl and alkylaryl groups, and cycloalkyl groups, including alkyl-substituted cycloalkyl and cycloalkyl-substituted alkyl groups, with such groups, if desired, being substituted with any of the substituents listed herein above. When cyclic groups are present, whether aromatic or nonaromatic, it is preferred that they have only one ring. The term "water soluble" shall denote a solubility in an amount of at least 2.5%, by weight, at a temperature of 90°C in deionized water. Preferably the comonomers are soluble in water to the extent of at least 5%, and most preferably at least 15%, by weight. Preferred organic radicals for compounds (a), (b), and (c) are, in general, free of olefinic and alkynyl linkages and also free of aromatic groups. In compound (a), it is further preferred that R₁, R₂, and R₃ be hydrogen or unsubstituted cycloalkyl or unsubstituted, straight or branched alkyl groups which have no more than 7 carbon atoms, with the exception that at least one of R₁, R₂, and R₃ may either be or bear a nitrile or a carboxylate group, wherein R₁₄ is hydrogen or an organic radical, usually having no more than 10 carbon atoms. More preferably, R₁, R₂, and R₃, except for the group or groups being or bearing the nitrile or carboxylate group, are hydrogen or unsubstituted, straight or branched chain alkyl groups having no more than 5 carbon atoms. When X is an organic radical, it preferably has no more than 6 carbon atoms and is an unsubstituted, branched or unbranched alkyl or unsubstituted cycloalkyl radical and, when an alkyl group, is most preferably unbranched. In the most preferred form of all, compound (a) is a dicarboxylic acid wherein R₁, R₂, and R₃ are all independently hydrogen, carboxylate groups, or ethyl or methyl groups, either unsubstituted or substituted with a carboxylate group, provided that R₁, R₂, and R₃ comprise, in total, only one carboxylate group. Most preferred for R₄ and R₁₄ are hydrogen and unsubstituted alkyl or unsubstituted cycloalkyl groups, provided at least one of R₄ and R₁₄ is hydrogen. Most preferred for X is a covalent bond. In particular regard to the most preferred embodiment of the water-soluble comonomer of compound (a), it is still more preferred that, except for the carboxylate groups, the remainder of the compound be hydrocarbyl; i.e., consist of only carbon and hydrogen atoms, and that the maximum number of carbon atoms in the compound be 27; with R₁ and R₂ combined having no more than 9, and R₃ no more than 8; with R₄ and R₁₄ having no more than 7 carbon atoms, provided that at least one of R₄ and R₁₄ is hydrogen. In the very most preferred embodiment, each side of the olefinic linkage has no more than about 5 carbon atoms, at least one of R₁, R₂, and R₃ is or contains the carboxylate group, and both of R₄ and R₁₄ are hydrogen. For compound (b), it is preferred that R₅, R₆, and R₇ be free of carboxylate substituents and, even more preferably, that they be hydrogen or unsubstituted cycloalkyl or unsubstituted, straight or branched alkyl groups which have no more than 7 carbon atoms. Most preferably, R₅, R₆, and R₇ are hydrogen or straight or branched, unsubstituted alkyl groups having no more than 5 carbon atoms. In the very most preferred form of all, R₅, R₆, and R₇, are all independently ethyl, methyl, or hydrogen. Preferred for R₈ and R₉ are hydrogen or unsubstituted, branched or unbranched, alkyl or unsubstituted cycloalkyl groups each having no more than 6 carbon atoms, provided that at beast one of R₈ and R₉ is hydrogen. When Y is an organic radical, it is preferably an unsubstituted, branched or unbranched, alkyl or unbranched cycloalkyl group with no more than 6 carbon atoms and, when an alkyl group, is more preferably unbranched. However, most preferred for Y is a covalent bond. For compound (c), it is preferred that R₁₀, R₁₁, and R₁₂ be free of hydroxyl and carboxylate substituents and, even more preferably, that they be hydrogen or unsubstituted cycloalkyl or unsubstituted, straight or branched chain alkyl groups which have no more than 7 carbon atoms. Most preferably, R₁₀, R₁₁, and R₁₂ are hydrogen or unsubstituted, straight or branched chain alkyl groups having no more than 5 carbon atoms. In the very most preferred form of all, R₁₀, R₁₁, and R₁₂ are all independently ethyl, methyl, or hydrogen. R₁₃ is also preferably free of carboxylate groups and is most preferably an alkyl or cycloalkyl group, with the required hydroxyl group being substituted at least 2 carbon atoms away from the carboxylate group. When Z is an organic radical, it is preferably a branched or unbranched, unsubstituted alkyl or unsubstituted cycloalkyl group with no more than 6 carbon atoms and, when an alkyl group, is preferably unbranched. However, most preferred for Z is a covalent bond. Suitable polymerizable, water-soluble monomers for compound (a) according to the above most preferred description include monoolefinically unsaturated diacids, such as tetrahydrophthalic acid, methylenesuccinic acid (itaconic acid), the cis- and trans- forms of butenedioic acid (maleic and fumaric acids), and both the cis- and trans- forms (where such exist) of the diacids resulting when one or more of the hydrogen atoms on the carbon chains of maleic/fumaric acid or itaconic acid is replaced with a methyl or ethyl group, as well as the C₁ to C₁₀ and, preferably, C₁ to C₅ semi-esters of these acids. Of these, itaconic acid and maleic acid are most preferred. Preferred polymerizable water-soluble, unsaturated compounds according to the above most preferred description for formula (b) are the primary and secondary amides of acrylic and methacrylic acid, with R₈ being hydrogen and R₉ being either hydrogen, methyl, or ethyl. Of the amido compounds meeting these criteria, acrylamide is most preferred. Preferred polymerizable, water-soluble, unsaturated compounds according to the above most preferred description for compound (c) are the hydroxy alkyl and hydroxy cycloalkyl esters of acrylic and methacrylic acids, and while the esterifying moiety must have at least 2 carbon atoms, it preferably has no more than 6, and, more preferably, no more than 4 carbon atoms. Of the hydroxy alkyl and hyroxy cycloalkyl esters of acrylic and methacrylic acids meeting these criteria, 2-hydroxyethyl acrylate is most preferred. The copolymerization reaction is conducted with between 0.1 part and 9 parts, by weight, of either compound (b) alone or each of compounds (b) and (c) together, for each part of compound (a). The fast curing binder compositions of the present invention are typically formed when between 2% and 20%, by weight, of an aqueous solution of the resultant solution copolymer is admixed with a polymeric carrier latex which is, in turn, formulated with between 2% and 15% of a non-formaldehyde emitting reactive monomer. Such an admixture, when cured at a suitable temperature on a matrix of nonwoven cellulosic material, will bind said material with at least 80% of fully cured wet tensile strength in 8 seconds or less. As used herein, the terms "non-formaldehyde" and "zero formaldehyde", when used in relation to the binders of the present invention, shall be taken to mean that a free formaldehyde level of 10 ppm or less is observed in the fully cured compositions. Such a level is close to the minimum level of detectability for most analytical methods and well below the level known to cause respiratory and skin irritation problems in people. The term "fully-cured" shall mean the wet tensile strength observed after a 25-second cure time. In the first embodiment of the present invention, a comonomeric mixture comprising between 0.1 and 9.0 parts, by weight, and, preferably, between 0.3 and 3 parts, by weight, of compound (b) to 1 part of one of the acid monomers of compound (a), particularly the dicarboxylic acid forms thereof, has been found to be particularly efficacious in producing a solution copolymer for the fast-curing binders of the present invention. In the second embodiment of the present invention, the comonomeric mixture preferably comprises between 0.3 and 3.0 parts, by weight, but, more preferably, between 0.75 and 1.5 parts, by weight, of each of the preferred compounds for (b) and (c) to 1 part of one of the preferred dicarboxylic acid monomers of compound (a). In addition to the basic comonomeric charge, as described above, one can also add a number of other agents to the mixture. It will be understood that any percentage values hereinafter given and in the claims for such agents are each based on the basic monomeric charge. Thus, the solution copolymeric composition may optionally contain up to about 20 weight percent of one or more polymerizable, monoolefinically unsaturated nonionic monomers to serve as extenders, T g modifiers, etc. without significantly degrading its basic properties. Suitable additive monomers for such purposes include the C₁ to C₅ saturated esters of acrylic and methacrylic acid, vinylidene chloride and vinyl compounds such as vinyl chloride, vinyl acetate, styrene, and the like. Preferred additive monomers are ethyl acrylate, butyl acrylate and styrene. Suitable copolymers of components (a), (b), and (c) can be prepared by either thermal or, preferably, free-radical initiated solution polymerization methods. Further, the reaction may be conducted by batch, semi-batch, and continuous procedures, which are well known for use in conventional polymerization reactions. Where free-radical polymerization is used, illustrative procedures suitable for producing aqueous polymer solutions involve gradually adding the monomer of monomers to be polymerized simultaneously to the respective percentage of each monomer in the finished copolymer and initiating and continuing said polymerization with a suitable reaction catalyst. Optionally, one or more of the comonomers can be added disproportionately throughout the polymerization so that the polymer formed during the initial stages of polymerization will have a composition and/or a molecular weight differing from that formed during the intermediate and later stages of the same polymerization reaction. Illustrative water-soluble, free-radical initiators are hydrogen peroxide and an alkali metal (sodium, potassium, or lithium) or ammonium persulfate, or a mixture of such an initiator in combination with a reducing agent activator, such as a sulfite, more specifically an alkali metabisulfite, hyposulfite or hydrosulfite, glucose, ascorbic acid, erythorbic acid, etc. to form a "redox" system. Normally the amount of initiator used ranges from about 0.01% to about 5%, by weight, based on the monomer charge. In a redox system, a corresponding range (about 0.01 to about 5%) of reducing agent is normally used. The reaction, once started, is continued, with agitation, at a temperature sufficient to maintain an adequate reaction rate until most, or all, of the comonomers are consumed and until the solution reaches a polymer solids concentration between 1% and 50%, by weight. Normally, the solids content will be kept above 10% to minimize drying problems when the binder is applied to cellulosic materials. At this point, the solution normally will have a viscosity in the range between 5 and 5000 CPS. Where experience has shown that a given comonomeric mixture will form a copolymeric solution having a viscosity in excess of 5000 CPS, between 0.1 and 5% of a suitable chain transfer agent may also be added to the reaction mixture to produce a lower molecular weight solution copolymer having a final viscosity within the 5 to 5000 CPS range. Examples of suitable chain transfer agents are organic halides such as carbon tetrachloride and tetrabromide, alkyl mercaptans, such as secondary and tertiary butyl mercaptan, and thio substituted polyhydroxyl alcohols, such as monothioglycerine. In the present invention, reaction temperatures in the range of 10°C to 100°C will yield satisfactory polymeric compositions. When persulfate systems are used, the solution temperature is normally in the range of 60°C to 100°C, while, in redox systems, the temperature is normally in the range of 10°C to 70°C, and preferably 30°C to 60°C. The binder composition of the present invention is formed when an amount of the aqueous solution copolymer comprising the reaction product of either of the embodiments described above is admixed with a fast-curing polymeric carrier latex. There are a number of commercially available zero formaldehyde latex carriers which, as basically formulated, would meet this requirement. These include styrene-butadiene resin (SBR) copolymers having between about 50% and about 70% styrene therein, carboxylated SBR copolymers (i.e., an SBR composition in which between 0.2% and 10% of one or more ethylenically unsaturated mono- or dicarboxylic acid monomers, such as acrylic acid, methacrylic acid, itaconic acid, maleic acid or fumaric acid, is copolymerized therewith), vinyl acetate/acrylate copolymers (which may also have up to about 5% of one or more ethylenically unsaturated mono- or dicarboxylic acid monomers added thereto) and all-acrylate copolymer latices. Several rheological properties of water base latices, such as those described above, are of particular importance when they are to be applied to the formulation of binders for cellulosic materials. For example, in many cases, control of latex particle size and particle size distribution is critical to the realization of desirable physical properties in the finished latex. Further, control of latex viscosity is an important factor due to its influence on polymer distribution, filler loading, and fiber wetting. While all of the polymer systems listed above may be polymerized using conventional emulsion polymerization techniques, this is frequently done in the presence of an added seed polymer to optimize these factors. In addition, while such latices may have either a unimodal or polymodal particle distribution, they are typically unimodal with a particle size in the range between 100 and 400 nm, a viscosity in the range between 20 and 2000 CPS, and a solids content in the range of 25% and 65%. To impart the fast-curing properties needed for cellulose binder compositions, the latices may be formulated with an amount of a cross-linker or other reactive monomer being added during the formulation thereof. The most effective prior art cross-linkers commonly used with these latices are all known formaldehyde emitters, such as methoxymethyl melamine, N-methylolacrylamide, and glyoxal bisacrylamide. In yet another aspect of the present invention, it has been found that in the production of these latexes, these formaldehyde emitting cross-linking materials can be entirely replaced with between 1/2% and 15%, by weight, of one or more low or non-formaldehyde emitting, polymerizable reactive monomers, selected from methyl acryloamidoglycolate methyl ether (MAGME) and isobutoxymethyl acrylamide (IBMA). Such monomers have been found to be especially effective in producing fast-curing, zero formaldehyde latex carriers. It has been found that latices so formulated, when combined with the solution polymers of this invention, form finished binder compositions having wet tensile strengths substantially equivalent or superior to those of prior art cellulose formaldehyde emitting binders. Further, this replacement has also been unexpectedly found to be especially advantageous in producing binder compositions which, when cured, retain their wet strength for significantly longer periods of time, as compared to the binder compositions of the prior art. For example, after being kept moist for a period of 8 days at 67°C, cured test strips treated with a binder of the present invention retained 20% of their initial wet strength, while those treated with a widely used prior art formaldehyde emitting binder retained only 12%. (See Comparative Example 3 below). When MAGME is used as a reactive monomer, the use of longer, lower temperature polymerization (i.e., 6 hours at 65°C followed by 5 hours at 75°C, as compared to a more commonly used 6 hours at 75°C followed by 3 hours at 90°C) is preferred to produce the finished latex carrier. When this is done, it is found that 5% improvement is evident in the cured wet tensile strength obtained in the finished binder (See Example 4 below). Formation of the final binder composition is accomplished by admixing one of the above described zero formaldehyde latex carrier latices with between 2% to 30%, and more preferably from 3% to 15%, and most preferably from 5% to 12%, by weight, of either embodiment of the solution copolymers of the present invention, as defined herein above. This is normally followed by diluting said admixture with sufficient deionized water to produce a total nonvolatile solids level between 3% and 20% and preferably between 8% and 15%. Depending on the particular application involved, other solids levels may be equally effective. When this is done, a binder composition according to the present invention is produced. When cured at 190°C for between 4 and 8 seconds on a nonwoven cellulosic material, such compositions will have wet tensile strengths which are as much as 50% higher than those obtainable with the basic carrier latex alone. In determining the residual formaldehyde content in the cured binder, it has been found that a critical aspect of such assessment is the method by which the measurement is made. In a widely used analytical method (the Nash/Hantzsch method), the high reactivity of the formaldehyde molecule with acetylacetone and ammonium carbonate is used to form highly colored diacetyllutedine, which is quantifiable by spectrophotometric methods. (See Nash, Biochem. J., Vol. 55, pages 416 - 421 (1953)). However, more recent work has shown that this method is not entirely specific to formaldehyde and will react with other materials such as acetaldehyde, IBMA, and MAGME to produce colored reactants which are often incorrectly reported as being formaldehyde. In the studies leading to the present invention, such a problem was avoided by the use of a modified polarographic method which was found to be highly specific to formaldehyde (See Larson, G, "The Electrochemical Determination of Formaldehyde in Monomers, SBR Emulsions and Nonwoven Products", Proceedings of the 1988 TAPPI Nonwovens Conference). All of the formaldehyde levels reported herein are based on the use of this method. A second factor typifying these latices is that many of those provided commercially have pH values as low as 2.0. Similarly, when the solution copolymeric reaction is completed, the final aqueous solution will also normally have a pH in the range between 2.0 to 3.0. While a blended composition having such a level of acidity will produce some degree of cellulosic wet strength, it has been found that neutralizing this acidity with a base, such as sodium hydroxide or, preferably, with ammonium hydroxide to a value of between 4.0 and 10.0, will produce final binder compositions having considerably improved wet strength. The invention is further described by the following examples. All percentages are by weight unless otherwise specified. EXAMPLES Example 1 A mixture comprised of 67 grams of each of 2-hydroxyethyl acrylate, itaconic acid, and acrylamide, and about 1154 cc of deionized water, was heated to a temerture of about 75°C, after which a solution of an initiator, comprised of 2 grams of sodium persulfate dissolved in about 10 cc of deionized water, was added. This mixture was then heated at 75°C for 3 hours, after which the resultant copolymer was neutralized to a pH of about 4.0 to 5.0 with concentrated ammonium hydroxide. After cooling and filtering, about 3%, be weight, of the resulting solution copolymer was admixed with a "standard" comercial non-formaldehyde emitting carboxylated SBR copolymer latex comprised of about 57% styrene, 38% butadiene, 3% acrylic acid, and 2% itaconic acid, the admixture then being neutralized with concentrated ammonia to a pH of about 8.0 and diluted with deionized water to achieve a nonvolatile solids content of about 12%. To determine wet strength improvement, two sets of 2.54 cm (1"-wide), nonwoven, randomly-oriented cellulose strips were them impregnated with the admixed carrier latex and with the binder composition as described above and, after being cured at about 200°C for 4, 6, 8, 10, 15 and 25 seconds, were dipped in a 1% surfactant solution, after which the wet tensile strength was measured with the following results: Wet Tensile Strength (PSI) Cure time: 4 sec 6 sec 8 sec 10 sec 15 sec 25 sec Binder Standard SBR + 0% solution polymer 4.8 6.8 8.2 8.4 9.6 9.7 Standard SBR + 3% solution polymer 6.0 9.6 9.4 10.1 10.3 11.2 Note that while both compositions achieved 8-second wet strengths of over 80% of the 25-second value, the 25-second wet tensile strength achieved by the "3%" binder was almost 15% higher than that shown by the basic SBR carrier latex alone. Comparative Example 1 The formaldehyde content and 6- and 180-second wet tensile strengths achieved with a widely used reference commercial cellulose binder composition comprising a carboxylated SBR latex (53.5% butadiene, 43.5% styrene, 2% N-methylol acrylamide, and 1/2% each of acrylamide and itaconic acid) cross-linked with 6% methoxymethyl melamine (Cymel 303, supplied by The Americal Cyanamid Co.), a known formaldehyde emitter, were compared to the values obtained with samples of both a vinyl acetate/acrylate latex, copolymerized with and without nominal "10%" isobutoxymethyl acrylamide (IBMA), and a SBR copolymer latex, copolymerized with and without nominal "10%" MAGME, with the following results: Binder Wet Tensile Strength (PSI) Formaldehyde Content ppm 6 sec (@ 188°C) 180 sec (@ 149°C) "Reference" SBR + 6% Cymel 303 7.9 7.9 480 Vinyl latex + 0% IBMA 1.8 4.8 10 Vinyl latex + 10% IBMA 5.5 6.7 10 SBR latex + 0% MAGME 2.6 5.7 10 SBR latex + 10% MAGME 6.7 7.0 10 This is an example of a binder with components (a), (b), and (c) of the present invention forming the solution polymer, the results of which are seen in the bottom 4 rows of the above table. Note that the compositions formulated according to the present invention are listed as exhibiting formaldehyde contents below 10 ppm, after curing. As a practical matter, this means that, in these compositions, formaldehyde was essentially undetectable. Example 2 The procedure of Example 1 was followed but with the solution polymer being formed with 200 grams of a 1:3 mixture of itaconic acid and acrylamide, respectively, dissolved in 1127 grams of deionized water, said mixture being reacted with 1% (2.0 grams) of sodium persulfate dissolved in 18 grams of deionized water at 75°C for about 3 hours. The reaction product was a copolymer solution having a viscosity of 107 CPS, a total solids content of about 15.6 and a pH of 4.1 after adjustment with ammonium hydroxide. 7.7 grams (wet) of this product was admixed with 49.5 grams (wet) of a base SBR polymer latex comprised of 57.6% styrene, 32.4% butadiene, 9% MAGME and 1% itaconic acid and diluted with sufficient deionized water to achieve a binder composition having a nonvolatile solids content of about 12%. A nonwoven cellulosic material was then impregnated with the so diluted composition to obtain about a 10% add-on, by dry weight. This material, after curing the binder at 190°C, was tested as described in Example 1, with the following results: Binder Wet Tensile Strength (PSI) 4 sec 6 sec 8 sec 180 sec (@ 149°C) (@190°C) Base SBR + 0% solution polymer 6.1 6.8 7.3 7.1 Base SBR + 10% solution polymer 6.0 7.6 8.6 8.9 Example 3 The procedure of Example 2 was followed but with 200 grams of a 1:1 mixture of itaconic acid and acrylamide being used. The final reaction product had a solution viscosity of 22 CPS and a solids content of 15.4%. The solution was then adjusted to a pH of 3.9 with ammonium hydroxide and, after being admixed and cured as described in Example 2, was tested as therein described. The results achieved were as follows: Binder Wet Tensile Strength (PSI) 4 sec 6 sec 8 sec 180 sec (@ 149°C) (@190°C) Base SBR + 0% solution polymer 6.1 6.8 7.3 7.1 Base SBR + 10% solution polymer 5.5 8.9 9.2 9.5 Examples 2 and 3 illustrate (in the bottom row of the above tables) the results achieved with a solution polymer containing only compounds (a) and (b). Comparative Example 2 The procedure of Comparative Example 1 was repeated with the binders of Examples 2 and 3 of the present invention being compared to the "Reference" formaldehyde emitting composition described therein, with the following test results: Binder Wet Tensile Strength (PSI) Formaldehyde Content (ppm) 6 sec (@ 190°C) 180 sec (@ 150°C) "Reference" SBR + 6% Cymel 303 7.9 7.9 480 Example 2 binder 6.5 7.9 10 Example 3 binder 7.5 8.0 10 Note that with both compositions of the present invention, the binder with a 10% addition of solution polymer achieved wet strength results at least equal to the reference formaldehyde-emitting binder. Comparative Example 3 The procedure of Comparative Example 1 was repeated with the finished binder compositions being soaked in a 1% solution of Aerosol OT for 8 days and showing the following results: Binder Wet Tensile Strength (PSI) After 6 sec After 8 days "Reference" SBR + 6% Cymel 303 7.9 1.0 SBR latex + 5% MAGME 5.1 0.7 SBR latex + 5% MAGME and 5% solution polymer (the invention) 6.5 1.3 Note that the residual wet strength of the binder of the present invention was 30% higher, after 8 days, than that of the reference formaldehyde emitting binder. Example 4 A first copolymeric latex comprised of a mixture of 64% styrene, 35% butadiene and 1% itaconic acid and 1% of a polystyrene seed polymer, with about 5% MAGME added thereto, was prepared at a temperature of about 74°C. The wet tensile strength results obtained were compared to those obtained with a second copolymeric latex comprised of 57% styrene, 38% butadiene, 2% itaconic acid and 3% acrylic acid with 0% MAGME being added thereto and reacted at 79°C, after both latices were admixed with 10% of the solution polymer of Example 1, neutralized with concentrated ammonium hydroxide to a pH of about 4.0 and diluted with deionized water to achieve a total nonvolatile solids content of about 12%. The results were as follows: Wet Tensile Strength (PSI) 4 sec 6 sec 8 sec 180 sec SBR +0% MAGME 3.4 4.8 5.8 8.0 SBR +5% MAGME 6.9 7.4 7.7 9.2 This shows that a compounded binder comprising a latex carrier which had been polymerized at a low temperature with 5% MAGME can achieve superior wet strength as compared to a basically similar composition comprised of a latex polymerized even at a slightly higher temperature without MAGME.

Claims: A fast-curing, zero-formaldehyde binder for nonwoven cellulosic materials, said binder comprising a solution copolymer formed by the reaction of a first water-soluble comonomer comprised of one or more olefinically unsaturated compounds having at least one carboxylate group, said compounds having the general formula: wherein R₁, R₂ and R₃ are independently selected from hydrogen, halogen, nitro, amino and organic radicals; and R₄ is hydrogen or an organic radical; and X is an organic radical or a covalent bond, with a second water-soluble comonomer comprised of one or more amides of olefinically unsaturated carboxylic acids, said amides having the general formula: wherein R₅, R₆ and R₇ are independently selected from hydrogen, halogen, nitro, amino and organic radicals; R₈ and R₉ are hydrogen or organic radicals; and Y is an organic radical or a covalent bond, with said solution copolymer being admixed in an amount between 2% to 20%, by weight, with a non-formaldehyde emitting latex carrier formulated with between 2% and 15%, by weight, of a substantially non-formaldehyde forming reactive monomer selected from methylacryloamido glycolatemethyl ether and isobutoxymethyl acrylamide to produce said binder. A process for making a fast-curing, zero formaldehyde binder for nonwoven cellulosic materials defined in claim 1, the process comprising: (a) reacting a mixture of the said water-soluble comonomer with the said second water-soluble comonomer; said reaction being carried out with between 0.5 part and 4 parts, by weight, of said second comonomer for each part of said first comonomer to produce a solution copolymer; and (b) admixing said solution copolymer with said non-formaldehyde emitting latex carrier. A binder according to claims 1 or 2, wherein said solution copolymer further comprises a third water-soluble comonomer comprised of one or more hydroxyalkyl esters of olefinically unsaturated carboxylic acids, said ester having the general formula: wherein R₁₀, R₁₁ and R₁₂ are independently selected from hydrogen, halogen, nitro, amino and organic radicals; R₁₃ is an organic radical having at least 2 carbon atoms, with at least one of R₁₁, R₁₂ and R₁₃ being an organic radical containing a hydroxyl substituent thereon, said hydroxyl substituent being located on a carbon atom which is at least 2 carbon atoms away from the carboxylate group shown in the above formula; and Z is an organic radical or covalent bond. A binder according to claims 1, 2 or 3, wherein all of said organic radicals are free of olefinic alkynyl linkages, all of said radicals further containing no more than 15 carbon atoms, and are preferably selected from substituted and unsubstituted alkyl, aryl, arylalkyl, alkylaryl, cycloalkyl, alkyl-substituted cycloalkyl and cycloalkyl-substituted alkyl groups having no more than one ring, and alkyl groups. A binder according to any one of claims 1 to 4, wherein R₁ through R₉ are independently selected from hydrogen or organic radicals, at least one of R₈ and R₉ being hydrogen. A binder according to claims 2, 3, 4 or 5, wherein R₁₀, R₁₁ and R₁₂ are independtly selected from hydrogen, methyl or ethyl; and R₁₃ is an alkyl chain having from 2 to 6 carbon atoms with the required hydroxyl group being a substituent thereon. A binder according to any one of the preceding claims, wherein said first comonomer comprises at least 2 carboxylate groups with at least one of R₁, R₂ and R₃ being either a group on an otherwise unsubstituted, unbranched alkyl group with a group substituted thereon, wherein R₁₄ is hydrogen or a hydrocarbyl radical having no more than 10 carbon atoms, the remaining radicals in said first and second comonomers being hydrogen or hydrocarbyl groups of no more than 10 carbon atoms. A binder according to any one of the preceding claims, wherein the maximum number of carbon atoms in said first comonomer is 27; X and Y are colvalent bonds; R₁, R₂ and R₃ combined have no more than 17 carbon atoms, with R₁ and R₂ having no more than 9 carbon atoms combined; R₄ and R₁₄ are hydrogen or an unsubstituted alkyl group having no more than 7 carbon atoms, at least one of R₄ and R₁₄ being hydrogen. A binder according to any one of the preceding claims, wherein R₅, R₆ and R₇ are independently selected from hydrogen, methyl or ethyl and both of R₈ and R₉ are hydrogen. A binder according to any one of the preceding claims, wherein said first comonomer is selected from tetrahydrophthalic acid, and cis- and trans- forms of butenedioic acid, methylenesuccinic acid and the diacids resulting when one or more of the hydrogen atoms on the carbon chains of butenedioic acid or methylenesuccinic acid is replaced with ethyl or methyl groups, and the C₁ and C₅ semi-esters of said acids. A binder according to any preceding claim, wherein R₅, R₆ and R₇ of said second monomer are independently selected from hydrogen, methyl and ethyl; both of R₈ and R₉ are hydrogen; and Y is a covalent bond. A binder according to any one of the preceding claims, wherein said first comonomer is selected from maleic acid and itaconic acid and said second comonomer is acrylamide. A binder according to claims 2 and 12, wherein said third comonomer is 2-hydroxethyl acrylate. A binder according to any one of claims 2 to 12, wherein said first comonomer comprises at least 2 carboxylate groups with at least one of R₁, R₂, and R₃ being either a group or an otherwise unsubstituted, unbranched alkyl chain with a group unsubstituted thereon, where R₁₄ is hydrogen or a hydrocarbyl group having no more than 10 carbon atoms: with the remaining radicals in said first comonomer being hydrogen or hydrocarbyl groups having no more than 10 carbon atoms, at least one of R₄ and R₁₄ being hydrogen; wherein R₅, R₆ and R₇ of said second monomer and R₁₀, R₁₁ and R₁₂ of said third monomer are independently selected from hydrogen, methyl, or ethyl, both of R₈ and R₉ are hydrogen, R₁₃ of said third comonomer has from 2 to 4 carbon atoms and the required hydroxyl group as a substituent thereon, and X, Y and Z are all covalent bonds. A binder according to any one of the preceding claims, wherein said solution copolymer is formed by the reaction of a mixture of one part of said first water-soluble comonomer with between 0.1 and 9 parts, by weight, of a second water-soluble comonomer selected from one or more of the primary amides of acrylic and methacrylic acid and the methyl and ethyl substituted secondary amides of acrylic and methacrylic acid. A binder according to any one of claims 1 to 15, wherein said solution polymer mixture further comprises up to 20% by weight, of one or more polymerizable, monoethylenically unsaturated nonionic monomers selected from C₁ to C₅ saturated esters of acrylic and methacrylic acid, vinyl acetate, vinyl chloride, styrene and vinylidene chloride. A binder according to any one of claims 1 to 15, wherein said solution copolymer is formed by the reaction of a mixture including a third water-soluble comonomer selected from one or more C₂ to C₄ hydroxyalkyl esters of acrylic acid or methacrylic acid, said third comonomer being present in an amount between 0.1 part and 9.0 parts, by weight, for each part of said first comonomer. A binder according to any one of claims 1 to 15, wherein said solution copolymer is formed by the reaction of a mixture of a first water-soluble comonomer selected from maleic acid and itaconic acid with acrylamide, in an amount between 0.5 part and 4.0 parts, by weight, of acrylamide, or acrylamide and 2-hydroxyethyl acrylate, for each part of said first comonomer and from 0.1% to 2%, by weight, of a second mixture comprised of equal parts of ethyl acrylate and styrene. A binder according to any preceding claim, wherein said latex is selected from styrene-butadiene copolymer, carboxylated styrene-butadiene copolymer, vinyl acetate/acrylate copolymer and all-acrylate polymer latices, and the amount of solution polymer product admixed therewith is in the range of 0.5% and 20%, by weight. A binder according to claim 19, wherein said admixed latex is diluted with water to achieve a total amount of nonvolatile solids in said latex between 3% and 20%.

Inventors: STACK DENNIS P, STEINWAND PAUL, STACK, DENNIS P., STEINWAND, PAUL
Applicants: ROHM & HAAS, ROHM AND HAAS COMPANY
Application year: 1989
Main classification: D04H1
IPC codes: C09J133, D04H1, C09J135, D06M15