Claims
- 1. A mixture adapted to form a bonded composite comprising nonwoven fibers having evenly distributed therewith a migration resistant binder composition comprising:
- (A) an anionically stabilized polymer latex;
- (B) a water-soluble polymer of 20% to 100% by weight of mer units containing an amine group and having a viscosity average molecular weight between 5,000 and 300,000;
- (C) a volatile base; and
- (D) 0 to 80% of pigment based on the total polymer weight of (A) and (B);
- the latex polymer and the water-soluble polymer each being a polymer of at least one .alpha.-.beta. ethylenically unsaturated monomer.
- 2. A composition according to claim 1 in which the water-soluble polymer is a copolymer of cationic and, optionally, nonionic vinyl monomers.
- 3. A composition according to claim 1 in which the water-soluble polymer is a polymer of a monomer of the formula ##STR5## wherein R is H or CH.sub.3 ; n is 0 or 1;
- X is O or N(H);
- A, when n is zero, is O(CH.sub.2).sub.x wherein x is 2 to 3, or (O-alkylene).sub.y wherein (O-alkylene).sub.y is a poly(oxyalkylene) group, having a molecular weight in the range from 88 to 348, in which the individual alkylene radicals are the same or different and are either alkylene or propylene; and
- A, when n is 1, is an alkylene group having two to 4 carbon atoms;
- R* is H, methyl, or ethyl; and
- R.degree. is H, phenyl, benzyl, methylbenzyl, cyclothexyl or C.sub.1 -C.sub.6) alkyl.
- 4. A composition according to claim 1 in which the water-soluble polymer is a polymer of a monomer of the formula ##STR6## wherein R is H or CH.sub.3 ; m is an integer having a value of 2 to 3; R', when not directly joined to R.sup.2, is selected from the group consisting of hydrogen, phenyl, benzyl, and (C.sub.1 -C.sub.12) alkyl groups;
- R.sup.2, when not directly joined to R', is selected from the group consisting of hydrogen and (C.sub.1 -C.sub.4) alkyl groups;
- R' and R.sup.2, when directly joined together, form a 5-to 6-carbon ring with the attached carbon atom of the ring in the formula; and
- A' is O(C.sub.m H.sub.2m) or (O-alkylene).sub.n in which (O-alkylene).sub.n is a poly(oxyalkylene) group, having a molecular weight in the range from 88 to 348, in which the individual alkylene radicals are the same or different and are either ethylene or propylene.
- 5. The composition of claim 1 in which the solids content is 10% to 60% by weight, the viscosity is below 3,000 centipoise, the pH is above 5, component (B) is between 0.1% and 20% by weight of the solids of (A) plus (B), and (A) is at least 50% by weight of the binder on a solids basis.
- 6. A composition according to claim 5 in which the latex polymer is a polymer or copolymer of a monomer selected from the group styrene, butadiene, vinyl acetate, vinyl chloride, vinylidene chloride, acrylonitrile, chloroprene, esters of acrylic acid and esters of methacrylic acid.
- 7. A composition according to claim 6 in which the latex polymer is a polymer or copolymer of a monomer selected from the group esters of acrylic acid and esters of methacrylic acid.
- 8. A composition according to claim 1 in which the water-soluble polymer is a polymer of at least 20% by weight of oxazolidinylethyl methacrylate.
- 9. A composition according to claim 8 in which the water-soluble polymer is a polymer of 40% to 100% by weight of oxazolidinylethyl methacrylate, has a viscosity average molecular weight between 40,000 and 100,000 and is 1% to 8% by weight of the solids of (A) plus (B), the composition having a pH between 7 and 8.5.
- 10. The composition of claim 9 in which the latex polymer is a polymer of monomers comprising, by weight:
- (a) 0.5 to 3% itaconic, acrylic or methacrylic acids or a mixture thereof;
- (b) 1 to 5% acrylamide, methacrylamide, methylol acrylamide, methylol methacrylamide or a mixture thereof;
- (c) 40 to 99% of an acrylic acid ester having 1 to 8 carbon atoms in the alcohol group or a mixture thereof;
- (d) 0 to 58% of a methacrylic acid ester having 1 to 8 carbon atoms in the alcohol group or a mixture thereof; and
- (e) 0 to 15% acrylonitrile.
- 11. The composition of claim 10 in which the monomers comprise, by weight:
- (a) 0.5 to 3% itaconic or acrylic acids or a mixture thereof;
- (b) 1 to 5% acrylamide or methylol acrylamide or a mixture thereof;
- (c) 80 to 98% of an acrylic acid ester having 1 to 4 carbon atoms in the alcohol group or a mixture thereof; and
- (d) 0 to 15% acrylonitrile.
- 12. A mixture adapted to form a bonded composite comprising nonwoven fibers having evenly distributed therewith a migration resistant binder composition comprising:
- (A) an anionically stabilized polymer latex;
- (B') a water-insoluble polymer of 20% to 100% by weight of mer units containing an amine group and having a viscosity average molecular weight between 5,000 and 100,000;
- (C) a volatile base; and
- (D) 0 to 80% of pigment based on the total polymer weight of (A) and (B);
- the latex polymer and the water-insoluble polymer each being a polymer of at least one .alpha.-.beta. ethylenically unsaturated monomer.
- 13. A composition according to claim 12 in which the water-insoluble polymer of (B') is a copolymer of cationic and optionally nonionic vinyl monomers.
- 14. A composition according to claim 12 in which the water-insoluble polymer of (B') is a polymer of a monomer of the formula ##STR7## wherein R is H or CH.sub.3 ; n is 0 or 1;
- X is o or N(H);
- A, when n is zero, is O(C.sub.2).sub.x wherein x is 2 to 3, or (O-alkylene).sub.y wherein (O-alkylene).sub.y is a poly(oxyalkylene) group, having a molecular weight in the range from 88 to 348, in which the individual alkylene radicals are the same or different and are either ethylene or propylene; and
- A, when n is 1, is an alkylene group having two to 4 carbon atoms;
- R* is H, methyl, or ethyl; and
- R.degree. is H, phenyl, benzyl, methylbenzyl, cyclohexyl, or (C.sub.1 -C.sub.6) alkyl.
- 15. A composition according to claim 12 in which the water-insoluble polymer of (B') is a polymer of a monomer of the formula ##STR8## wherein R is H or CH.sub.3 ; m is an integer having a value of 2 to 3;
- R', when not directly joined to R.sup.2, is selected from the group consisting of hydrogen, phenyl, benzyl, and (C.sub.1 -C.sub.12) alkyl groups;
- R.sup.2, when not directly joined to R', is selected from the group consisting of hydrogen and (C.sub.1 -C.sub.4) alkyl groups;
- R' and R.sup.2, when directly joined together, form a 5-to 6-carbon ring with the atttached carbon atom of the ring in the formula; and
- A' is O(C.sub.m -H.sub.2m) or (O-alkylene).sub.n in which (O-alkylene).sub.n is a poly(oxyalkylene) group, having a molecular weight in the range from 88 to 348, in which the individual alkylene radicals are the same or different and are either ethylene or propylene.
- 16. The composition of claim 12 in which the solids content is 10% to 60% by weight, the viscosity is below 3,000 centipoise, the pH is above 5 and component (B') is between 0.1% and 20% by weight of the solids of (A) plus (B'), and (A) is at least 50% by weight of the binder on a solids basis.
- 17. A composition according to claim 16 in which the latex polymer is a polymer or copolymer of a monomer selected from the group styrene, butadiene, vinyl acetate, vinyl chloride, vinylidene chloride, acrylonitrile, chloroprene, esters of acrylic acid and esters of methacrylic acid.
- 18. A composition according to claim 17 in which the latex polymer is a polymer or copolymer of a monomer selected from the group esters of acrylic acid and esters of methacrylic acid.
- 19. A composition according to claim 12 in which the water-insoluble polymer of (B') is a polymer of at least 20% by weight of oxazolidinylethyl methacrylate.
- 20. A composition according to claim 19 in which the water-insoluble polymer of (B') is a polymer of 30% to 70% by weight of oxazolidinylethyl methacrylate, has a viscosity average molecular weight between 15,000 and 90,000 and is 1% to 8% by weight of the solids of (A) plus (B'), the composition having a pH between 7 and 8.5.
- 21. The composition of claim 20 in which the latex polymer is a polymer of monomers comprising, by weight:
- (a) 0.5 to 3% itaconic, acrylic or methacrylic acids or a mixture thereof;
- (b) 1 to 5% acrylamide, methacrylamide methylol acrylamide, methylol methacrylamide or a mixture thereof;
- (c) 40 to 98% of an acrylic acid ester having 1 to 8 carbon atoms in the alcohol group or a mixture thereof;
- (d) 0 to 58% of a methacrylic acid ester having 1 to 8 carbon atoms in the alcohol group or a mixture thereof; and
- (e) 0 to 15% acrylonitrile.
- 22. The composition of claim 21 in which the monomers comprise, by weight:
- (a) 0.5 to 3% itaconic or acrylic acids or a mixture thereof;
- (b) 1 to 5% acrylamide or methylol acrylamide or a mixture thereof;
- (c) 80 to 98% of an acrylic acid ester having 1to 4 carbon atoms in the alcohol group or a mixture thereof; and
- (d) 0 to 15% acrylonitrile.
- 23. A nonwoven composite formed from the composition of claim 1.
- 24. The composite of claim 23 in which the fibers arepredominantly fibers selected from the group consisting of cellulosic fibers, polyamide fibers, glass fibers, vinyl resin fibers and polyester fibers.
- 25. A nonwoven composite formed from the composition of claim 12.
- 26. The composite of claim 25 in which the fibers are predominantly fibers selected from the group consisting of cellulosic fibers, polyamide fibers, glass fibers, vinyl resin fibers and polyester fibers.
- 27. A process for making a nonwoven composite which comprises associating, within a web or mat, fibers selected from the group consisting of cellulosic fibers, polyamide fibers, glass fibers, vinyl resin fibers and polyester fibers and bringing into contact with the fibers the binder of claim 1 and drying the binder.
- 28. A process of making a nonwoven composite which comprises associating, within a web or mat, fibers selected from the group consisting of cellulosic fibers, polyamide fibers, glass fibers, vinyl resin fibers and polyester fibers and bringing into contact with the fibers the binder of and drying the binder.
- 29. A process of non-woven fabric production which comprises subjecting to a drying operation the composition of claim 1 in sheet form wherein the fibers are selected from the group consisting of cellulosic fibers, polyamide fibers, glass fibers, vinyl resin fibers and polyester fibers.
- 30. A process of non-woven fabric production which comprises subjecting to a drying operation the composition of claim 12 in sheet form wherein the fibers are selected from the group consisting of cellulosic fibers, polyamide fibers, glass fibers, vinyl resin fibers and polyester fibers.
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. application Ser. No. 686,980 filed May 17, 1976, now U.S. Pat. No. 4,119,600 issued Oct. 10, 1978.
US Referenced Citations (3)
Continuation in Parts (1)
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Number |
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686980 |
May 1976 |
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