WO2024096808A1 - Biobased binder compositions for nonwoven materials - Google Patents
Biobased binder compositions for nonwoven materials Download PDFInfo
- Publication number
- WO2024096808A1 WO2024096808A1 PCT/SE2023/051119 SE2023051119W WO2024096808A1 WO 2024096808 A1 WO2024096808 A1 WO 2024096808A1 SE 2023051119 W SE2023051119 W SE 2023051119W WO 2024096808 A1 WO2024096808 A1 WO 2024096808A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- acid
- binder composition
- nonwoven material
- chitosan
- nonwoven
- Prior art date
Links
- 239000000463 material Substances 0.000 title claims abstract description 161
- 239000011230 binding agent Substances 0.000 title claims abstract description 144
- 239000000203 mixture Substances 0.000 title claims abstract description 136
- 229920001661 Chitosan Polymers 0.000 claims abstract description 32
- 239000004014 plasticizer Substances 0.000 claims abstract description 32
- 239000002253 acid Substances 0.000 claims abstract description 24
- 238000000034 method Methods 0.000 claims description 29
- 125000002091 cationic group Chemical group 0.000 claims description 24
- 229920000867 polyelectrolyte Polymers 0.000 claims description 23
- 239000004088 foaming agent Substances 0.000 claims description 20
- 229920002472 Starch Polymers 0.000 claims description 12
- 150000001720 carbohydrates Chemical class 0.000 claims description 12
- 239000008107 starch Substances 0.000 claims description 12
- 235000019698 starch Nutrition 0.000 claims description 12
- 239000000654 additive Substances 0.000 claims description 10
- 229920001448 anionic polyelectrolyte Polymers 0.000 claims description 10
- JVTAAEKCZFNVCJ-UHFFFAOYSA-N lactic acid Chemical compound CC(O)C(O)=O JVTAAEKCZFNVCJ-UHFFFAOYSA-N 0.000 claims description 10
- 239000002841 Lewis acid Substances 0.000 claims description 9
- 230000000996 additive effect Effects 0.000 claims description 9
- 239000003054 catalyst Substances 0.000 claims description 9
- 239000000945 filler Substances 0.000 claims description 9
- 239000007848 Bronsted acid Substances 0.000 claims description 8
- 239000003795 chemical substances by application Substances 0.000 claims description 8
- 150000007517 lewis acids Chemical class 0.000 claims description 8
- 229920000642 polymer Polymers 0.000 claims description 8
- 229920005862 polyol Polymers 0.000 claims description 8
- 150000003077 polyols Chemical class 0.000 claims description 8
- 239000003755 preservative agent Substances 0.000 claims description 8
- 230000002335 preservative effect Effects 0.000 claims description 8
- 239000004094 surface-active agent Substances 0.000 claims description 8
- FBPFZTCFMRRESA-FSIIMWSLSA-N D-Glucitol Natural products OC[C@H](O)[C@H](O)[C@@H](O)[C@H](O)CO FBPFZTCFMRRESA-FSIIMWSLSA-N 0.000 claims description 7
- FBPFZTCFMRRESA-JGWLITMVSA-N D-glucitol Chemical compound OC[C@H](O)[C@@H](O)[C@H](O)[C@H](O)CO FBPFZTCFMRRESA-JGWLITMVSA-N 0.000 claims description 7
- 229920000297 Rayon Polymers 0.000 claims description 7
- 239000013530 defoamer Substances 0.000 claims description 7
- 239000003995 emulsifying agent Substances 0.000 claims description 7
- 239000000049 pigment Substances 0.000 claims description 7
- 239000006254 rheological additive Substances 0.000 claims description 7
- 239000000600 sorbitol Substances 0.000 claims description 7
- 235000010356 sorbitol Nutrition 0.000 claims description 7
- 239000000080 wetting agent Substances 0.000 claims description 7
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 claims description 6
- 239000004971 Cross linker Substances 0.000 claims description 6
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 claims description 6
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 claims description 6
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 claims description 6
- TVXBFESIOXBWNM-UHFFFAOYSA-N Xylitol Natural products OCCC(O)C(O)C(O)CCO TVXBFESIOXBWNM-UHFFFAOYSA-N 0.000 claims description 6
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 claims description 6
- 239000000845 maltitol Substances 0.000 claims description 6
- VQHSOMBJVWLPSR-WUJBLJFYSA-N maltitol Chemical compound OC[C@H](O)[C@@H](O)[C@@H]([C@H](O)CO)O[C@H]1O[C@H](CO)[C@@H](O)[C@H](O)[C@H]1O VQHSOMBJVWLPSR-WUJBLJFYSA-N 0.000 claims description 6
- 235000010449 maltitol Nutrition 0.000 claims description 6
- 229940035436 maltitol Drugs 0.000 claims description 6
- HEBKCHPVOIAQTA-UHFFFAOYSA-N meso ribitol Natural products OCC(O)C(O)C(O)CO HEBKCHPVOIAQTA-UHFFFAOYSA-N 0.000 claims description 6
- 239000000811 xylitol Substances 0.000 claims description 6
- 235000010447 xylitol Nutrition 0.000 claims description 6
- HEBKCHPVOIAQTA-SCDXWVJYSA-N xylitol Chemical compound OC[C@H](O)[C@@H](O)[C@H](O)CO HEBKCHPVOIAQTA-SCDXWVJYSA-N 0.000 claims description 6
- 229960002675 xylitol Drugs 0.000 claims description 6
- 244000025254 Cannabis sativa Species 0.000 claims description 5
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 claims description 5
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 claims description 5
- FBPFZTCFMRRESA-KVTDHHQDSA-N D-Mannitol Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)[C@H](O)CO FBPFZTCFMRRESA-KVTDHHQDSA-N 0.000 claims description 5
- WQZGKKKJIJFFOK-QTVWNMPRSA-N D-mannopyranose Chemical compound OC[C@H]1OC(O)[C@@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-QTVWNMPRSA-N 0.000 claims description 5
- 229920001353 Dextrin Polymers 0.000 claims description 5
- 239000004375 Dextrin Substances 0.000 claims description 5
- 229930091371 Fructose Natural products 0.000 claims description 5
- 239000005715 Fructose Substances 0.000 claims description 5
- RFSUNEUAIZKAJO-ARQDHWQXSA-N Fructose Chemical compound OC[C@H]1O[C@](O)(CO)[C@@H](O)[C@@H]1O RFSUNEUAIZKAJO-ARQDHWQXSA-N 0.000 claims description 5
- WQZGKKKJIJFFOK-GASJEMHNSA-N Glucose Natural products OC[C@H]1OC(O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-GASJEMHNSA-N 0.000 claims description 5
- 229920000433 Lyocell Polymers 0.000 claims description 5
- 229930195725 Mannitol Natural products 0.000 claims description 5
- 239000004376 Sucralose Substances 0.000 claims description 5
- CZMRCDWAGMRECN-UGDNZRGBSA-N Sucrose Chemical compound O[C@H]1[C@H](O)[C@@H](CO)O[C@@]1(CO)O[C@@H]1[C@H](O)[C@@H](O)[C@H](O)[C@@H](CO)O1 CZMRCDWAGMRECN-UGDNZRGBSA-N 0.000 claims description 5
- 229930006000 Sucrose Natural products 0.000 claims description 5
- 229920002522 Wood fibre Polymers 0.000 claims description 5
- WQZGKKKJIJFFOK-VFUOTHLCSA-N beta-D-glucose Chemical compound OC[C@H]1O[C@@H](O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-VFUOTHLCSA-N 0.000 claims description 5
- 235000009120 camo Nutrition 0.000 claims description 5
- 235000005607 chanvre indien Nutrition 0.000 claims description 5
- 235000019425 dextrin Nutrition 0.000 claims description 5
- 239000008103 glucose Substances 0.000 claims description 5
- 239000011487 hemp Substances 0.000 claims description 5
- 239000004310 lactic acid Substances 0.000 claims description 5
- 235000014655 lactic acid Nutrition 0.000 claims description 5
- 239000000594 mannitol Substances 0.000 claims description 5
- 235000010355 mannitol Nutrition 0.000 claims description 5
- 229960001855 mannitol Drugs 0.000 claims description 5
- 229920000747 poly(lactic acid) Polymers 0.000 claims description 5
- 229960002920 sorbitol Drugs 0.000 claims description 5
- 238000005507 spraying Methods 0.000 claims description 5
- BAQAVOSOZGMPRM-QBMZZYIRSA-N sucralose Chemical compound O[C@@H]1[C@@H](O)[C@@H](Cl)[C@@H](CO)O[C@@H]1O[C@@]1(CCl)[C@@H](O)[C@H](O)[C@@H](CCl)O1 BAQAVOSOZGMPRM-QBMZZYIRSA-N 0.000 claims description 5
- 235000019408 sucralose Nutrition 0.000 claims description 5
- 239000005720 sucrose Substances 0.000 claims description 5
- 150000003445 sucroses Chemical class 0.000 claims description 5
- AEMRFAOFKBGASW-UHFFFAOYSA-N Glycolic acid Chemical compound OCC(O)=O AEMRFAOFKBGASW-UHFFFAOYSA-N 0.000 claims description 4
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 claims description 4
- LCTONWCANYUPML-UHFFFAOYSA-N Pyruvic acid Chemical compound CC(=O)C(O)=O LCTONWCANYUPML-UHFFFAOYSA-N 0.000 claims description 4
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 claims description 4
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 claims description 4
- 230000006196 deacetylation Effects 0.000 claims description 4
- 238000003381 deacetylation reaction Methods 0.000 claims description 4
- HHLFWLYXYJOTON-UHFFFAOYSA-N glyoxylic acid Chemical compound OC(=O)C=O HHLFWLYXYJOTON-UHFFFAOYSA-N 0.000 claims description 4
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 claims description 4
- 150000007522 mineralic acids Chemical class 0.000 claims description 4
- 150000007524 organic acids Chemical class 0.000 claims description 4
- YGSDEFSMJLZEOE-UHFFFAOYSA-N salicylic acid Chemical compound OC(=O)C1=CC=CC=C1O YGSDEFSMJLZEOE-UHFFFAOYSA-N 0.000 claims description 4
- 239000011248 coating agent Substances 0.000 claims description 3
- 238000000576 coating method Methods 0.000 claims description 3
- 239000002736 nonionic surfactant Substances 0.000 claims description 3
- QBYIENPQHBMVBV-HFEGYEGKSA-N (2R)-2-hydroxy-2-phenylacetic acid Chemical compound O[C@@H](C(O)=O)c1ccccc1.O[C@@H](C(O)=O)c1ccccc1 QBYIENPQHBMVBV-HFEGYEGKSA-N 0.000 claims description 2
- MIOPJNTWMNEORI-GMSGAONNSA-N (S)-camphorsulfonic acid Chemical compound C1C[C@@]2(CS(O)(=O)=O)C(=O)C[C@@H]1C2(C)C MIOPJNTWMNEORI-GMSGAONNSA-N 0.000 claims description 2
- BJEPYKJPYRNKOW-REOHCLBHSA-N (S)-malic acid Chemical compound OC(=O)[C@@H](O)CC(O)=O BJEPYKJPYRNKOW-REOHCLBHSA-N 0.000 claims description 2
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 claims description 2
- BSYNRYMUTXBXSQ-FOQJRBATSA-N 59096-14-9 Chemical compound CC(=O)OC1=CC=CC=C1[14C](O)=O BSYNRYMUTXBXSQ-FOQJRBATSA-N 0.000 claims description 2
- FEWJPZIEWOKRBE-JCYAYHJZSA-N Dextrotartaric acid Chemical compound OC(=O)[C@H](O)[C@@H](O)C(O)=O FEWJPZIEWOKRBE-JCYAYHJZSA-N 0.000 claims description 2
- IWYDHOAUDWTVEP-UHFFFAOYSA-N R-2-phenyl-2-hydroxyacetic acid Natural products OC(=O)C(O)C1=CC=CC=C1 IWYDHOAUDWTVEP-UHFFFAOYSA-N 0.000 claims description 2
- KDYFGRWQOYBRFD-UHFFFAOYSA-N Succinic acid Natural products OC(=O)CCC(O)=O KDYFGRWQOYBRFD-UHFFFAOYSA-N 0.000 claims description 2
- FEWJPZIEWOKRBE-UHFFFAOYSA-N Tartaric acid Natural products [H+].[H+].[O-]C(=O)C(O)C(O)C([O-])=O FEWJPZIEWOKRBE-UHFFFAOYSA-N 0.000 claims description 2
- 229960000583 acetic acid Drugs 0.000 claims description 2
- 239000001361 adipic acid Substances 0.000 claims description 2
- 235000011037 adipic acid Nutrition 0.000 claims description 2
- 229960000250 adipic acid Drugs 0.000 claims description 2
- BJEPYKJPYRNKOW-UHFFFAOYSA-N alpha-hydroxysuccinic acid Natural products OC(=O)C(O)CC(O)=O BJEPYKJPYRNKOW-UHFFFAOYSA-N 0.000 claims description 2
- 239000002280 amphoteric surfactant Substances 0.000 claims description 2
- 239000003945 anionic surfactant Substances 0.000 claims description 2
- SRSXLGNVWSONIS-UHFFFAOYSA-N benzenesulfonic acid Chemical compound OS(=O)(=O)C1=CC=CC=C1 SRSXLGNVWSONIS-UHFFFAOYSA-N 0.000 claims description 2
- 229940092714 benzenesulfonic acid Drugs 0.000 claims description 2
- KDYFGRWQOYBRFD-NUQCWPJISA-N butanedioic acid Chemical compound O[14C](=O)CC[14C](O)=O KDYFGRWQOYBRFD-NUQCWPJISA-N 0.000 claims description 2
- 239000003093 cationic surfactant Substances 0.000 claims description 2
- BZCOSCNPHJNQBP-OWOJBTEDSA-N dihydroxyfumaric acid Chemical compound OC(=O)C(\O)=C(/O)C(O)=O BZCOSCNPHJNQBP-OWOJBTEDSA-N 0.000 claims description 2
- 238000007865 diluting Methods 0.000 claims description 2
- 235000019253 formic acid Nutrition 0.000 claims description 2
- 229960005150 glycerol Drugs 0.000 claims description 2
- 235000011187 glycerol Nutrition 0.000 claims description 2
- 235000011167 hydrochloric acid Nutrition 0.000 claims description 2
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 claims description 2
- 239000011976 maleic acid Substances 0.000 claims description 2
- 239000001630 malic acid Substances 0.000 claims description 2
- 235000011090 malic acid Nutrition 0.000 claims description 2
- 229960002510 mandelic acid Drugs 0.000 claims description 2
- 235000006408 oxalic acid Nutrition 0.000 claims description 2
- FJKROLUGYXJWQN-UHFFFAOYSA-N papa-hydroxy-benzoic acid Natural products OC(=O)C1=CC=C(O)C=C1 FJKROLUGYXJWQN-UHFFFAOYSA-N 0.000 claims description 2
- 229940107700 pyruvic acid Drugs 0.000 claims description 2
- 229960004889 salicylic acid Drugs 0.000 claims description 2
- 229940032330 sulfuric acid Drugs 0.000 claims description 2
- 239000011975 tartaric acid Substances 0.000 claims description 2
- 229960001367 tartaric acid Drugs 0.000 claims description 2
- 235000002906 tartaric acid Nutrition 0.000 claims description 2
- JOXIMZWYDAKGHI-UHFFFAOYSA-N toluene-4-sulfonic acid Chemical compound CC1=CC=C(S(O)(=O)=O)C=C1 JOXIMZWYDAKGHI-UHFFFAOYSA-N 0.000 claims description 2
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 claims description 2
- 239000002025 wood fiber Substances 0.000 claims 1
- 238000011282 treatment Methods 0.000 abstract description 12
- 230000001747 exhibiting effect Effects 0.000 abstract description 3
- 239000004745 nonwoven fabric Substances 0.000 description 20
- 238000009864 tensile test Methods 0.000 description 20
- 239000000047 product Substances 0.000 description 13
- 239000006260 foam Substances 0.000 description 12
- 229940032147 starch Drugs 0.000 description 10
- 238000005470 impregnation Methods 0.000 description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 8
- 230000008569 process Effects 0.000 description 8
- 239000000835 fiber Substances 0.000 description 7
- -1 clays Chemical class 0.000 description 4
- 235000013312 flour Nutrition 0.000 description 4
- 238000009413 insulation Methods 0.000 description 4
- 229920002994 synthetic fiber Polymers 0.000 description 4
- 244000269722 Thea sinensis Species 0.000 description 3
- 238000001914 filtration Methods 0.000 description 3
- 235000013305 food Nutrition 0.000 description 3
- 239000004746 geotextile Substances 0.000 description 3
- 239000002002 slurry Substances 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 150000001412 amines Chemical class 0.000 description 2
- 125000000129 anionic group Chemical group 0.000 description 2
- 230000000844 anti-bacterial effect Effects 0.000 description 2
- 238000009960 carding Methods 0.000 description 2
- 125000004122 cyclic group Chemical group 0.000 description 2
- 238000010790 dilution Methods 0.000 description 2
- 239000012895 dilution Substances 0.000 description 2
- 230000009881 electrostatic interaction Effects 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 239000005003 food packaging material Substances 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- 230000002209 hydrophobic effect Effects 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- 150000002500 ions Chemical class 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 150000002678 macrocyclic compounds Chemical class 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000004753 textile Substances 0.000 description 2
- LUEWUZLMQUOBSB-FSKGGBMCSA-N (2s,3s,4s,5s,6r)-2-[(2r,3s,4r,5r,6s)-6-[(2r,3s,4r,5s,6s)-4,5-dihydroxy-2-(hydroxymethyl)-6-[(2r,4r,5s,6r)-4,5,6-trihydroxy-2-(hydroxymethyl)oxan-3-yl]oxyoxan-3-yl]oxy-4,5-dihydroxy-2-(hydroxymethyl)oxan-3-yl]oxy-6-(hydroxymethyl)oxane-3,4,5-triol Chemical compound O[C@H]1[C@@H](O)[C@H](O)[C@@H](CO)O[C@H]1O[C@@H]1[C@@H](CO)O[C@@H](O[C@@H]2[C@H](O[C@@H](OC3[C@H](O[C@@H](O)[C@@H](O)[C@H]3O)CO)[C@@H](O)[C@H]2O)CO)[C@H](O)[C@H]1O LUEWUZLMQUOBSB-FSKGGBMCSA-N 0.000 description 1
- 244000215068 Acacia senegal Species 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 244000247812 Amorphophallus rivieri Species 0.000 description 1
- 235000001206 Amorphophallus rivieri Nutrition 0.000 description 1
- YASYEJJMZJALEJ-UHFFFAOYSA-N Citric acid monohydrate Chemical compound O.OC(=O)CC(O)(C(O)=O)CC(O)=O YASYEJJMZJALEJ-UHFFFAOYSA-N 0.000 description 1
- 229920000858 Cyclodextrin Polymers 0.000 description 1
- 229920002581 Glucomannan Polymers 0.000 description 1
- 229920000084 Gum arabic Polymers 0.000 description 1
- 229920002752 Konjac Polymers 0.000 description 1
- 239000002879 Lewis base Substances 0.000 description 1
- 241000699670 Mus sp. Species 0.000 description 1
- 240000007817 Olea europaea Species 0.000 description 1
- 240000007594 Oryza sativa Species 0.000 description 1
- 235000007164 Oryza sativa Nutrition 0.000 description 1
- VYWQTJWGWLKBQA-UHFFFAOYSA-N [amino(hydroxy)methylidene]azanium;chloride Chemical class Cl.NC(N)=O VYWQTJWGWLKBQA-UHFFFAOYSA-N 0.000 description 1
- SSBRSHIQIANGKS-UHFFFAOYSA-N [amino(hydroxy)methylidene]azanium;hydrogen sulfate Chemical class NC(N)=O.OS(O)(=O)=O SSBRSHIQIANGKS-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000000205 acacia gum Substances 0.000 description 1
- 235000010489 acacia gum Nutrition 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 150000001450 anions Chemical class 0.000 description 1
- 230000001580 bacterial effect Effects 0.000 description 1
- 239000003899 bactericide agent Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 229920013724 bio-based polymer Polymers 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 210000004556 brain Anatomy 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 150000003857 carboxamides Chemical class 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 229960004106 citric acid Drugs 0.000 description 1
- 229960002303 citric acid monohydrate Drugs 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000007799 cork Substances 0.000 description 1
- 239000002537 cosmetic Substances 0.000 description 1
- 229940097362 cyclodextrins Drugs 0.000 description 1
- 239000008367 deionised water Substances 0.000 description 1
- 229910021641 deionized water Inorganic materials 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- SYELZBGXAIXKHU-UHFFFAOYSA-N dodecyldimethylamine N-oxide Chemical compound CCCCCCCCCCCC[N+](C)(C)[O-] SYELZBGXAIXKHU-UHFFFAOYSA-N 0.000 description 1
- 230000002255 enzymatic effect Effects 0.000 description 1
- HDERJYVLTPVNRI-UHFFFAOYSA-N ethene;ethenyl acetate Chemical group C=C.CC(=O)OC=C HDERJYVLTPVNRI-UHFFFAOYSA-N 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000005452 food preservative Substances 0.000 description 1
- 235000019249 food preservative Nutrition 0.000 description 1
- 230000000855 fungicidal effect Effects 0.000 description 1
- 239000000417 fungicide Substances 0.000 description 1
- 229940046240 glucomannan Drugs 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- 239000010903 husk Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 230000036512 infertility Effects 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 229920000831 ionic polymer Polymers 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 239000000252 konjac Substances 0.000 description 1
- 235000010485 konjac Nutrition 0.000 description 1
- 150000007527 lewis bases Chemical class 0.000 description 1
- 229920002521 macromolecule Polymers 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Chemical group 0.000 description 1
- 229910001510 metal chloride Inorganic materials 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical group 0.000 description 1
- 230000003278 mimic effect Effects 0.000 description 1
- 239000002362 mulch Substances 0.000 description 1
- 239000012766 organic filler Substances 0.000 description 1
- 239000008020 pharmaceutical preservative Substances 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 229920000447 polyanionic polymer Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 235000009566 rice Nutrition 0.000 description 1
- 150000004760 silicates Chemical class 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000001228 spectrum Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
- 229920001059 synthetic polymer Polymers 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 239000008399 tap water Substances 0.000 description 1
- 235000020679 tap water Nutrition 0.000 description 1
- 238000007669 thermal treatment Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J105/00—Adhesives based on polysaccharides or on their derivatives, not provided for in groups C09J101/00 or C09J103/00
- C09J105/08—Chitin; Chondroitin sulfate; Hyaluronic acid; Derivatives thereof
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L5/00—Compositions of polysaccharides or of their derivatives not provided for in groups C08L1/00 or C08L3/00
- C08L5/08—Chitin; Chondroitin sulfate; Hyaluronic acid; Derivatives thereof
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/18—Plasticising macromolecular compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L3/00—Compositions of starch, amylose or amylopectin or of their derivatives or degradation products
- C08L3/02—Starch; Degradation products thereof, e.g. dextrin
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
- D04H1/641—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions characterised by the chemical composition of the bonding agent
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
- D04H1/645—Impregnation followed by a solidification process
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H5/00—Special paper or cardboard not otherwise provided for
- D21H5/26—Special paper or cardboard manufactured by dry method; Apparatus or processes for forming webs by dry method from mainly short-fibre or particle material, e.g. paper pulp
- D21H5/265—Treatment of the formed web
- D21H5/2657—Consolidation
- D21H5/2664—Addition of a binder, e.g. synthetic resins or water
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2305/00—Characterised by the use of polysaccharides or of their derivatives not provided for in groups C08J2301/00 or C08J2303/00
- C08J2305/08—Chitin; Chondroitin sulfate; Hyaluronic acid; Derivatives thereof
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
- C08K5/0016—Plasticisers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/04—Oxygen-containing compounds
- C08K5/05—Alcohols; Metal alcoholates
- C08K5/053—Polyhydroxylic alcohols
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
- C09J11/02—Non-macromolecular additives
- C09J11/06—Non-macromolecular additives organic
Definitions
- the present invention relates to biobased binder compositions which are environmentally benign, renewable, compostable and/or biodegradable.
- the biobased compositions comprise chitosan, an acid and a plasticizer being a linear polyol and/or a non-macrocyclic saccharide.
- the invention further relates to a method of treating a nonwoven material with a biobased binder composition according to the present invention.
- compositions according to the present invention are suitable as a binder for different types of nonwoven materials.
- the treatment of various nonwoven materials with a binder composition according to the present invention provides nonwoven materials with excellent mechanical properties.
- the binder composition according to the present invention is easy to use for treatment of different types of nonwoven materials and can be adapted to provide specific properties to certain nonwoven materials and applications.
- Nonwoven materials are fabric-like materials made from long or short fibres, bonded together by a chemical, a mechanical, a heat or a solvent treatment.
- Nonwoven fabrics are also defined as sheet or web structures bonded together by entangling fiber or filaments (and by perforating films) mechanically, thermally or chemically.
- the term is used in the textile manufacturing industry to denote fabrics, such as felt, which are neither woven nor knitted. They are flat or tufted porous sheets that are made directly from separate fibres, molten plastic or plastic film.
- Nonwoven materials can provide specific functions such as absorbency, water repellence, softness, strength, flame retardancy, cushioning, thermal insulation, acoustic insulation, filtration, bacterial barrier and sterility. These properties are often combined to create fabrics suited for specific applications, while achieving a good balance between product use-life and cost. They can mimic the appearance, texture and strength of a woven fabric and can be as bulky as a thick padding. In combination with other materials, they provide a spectrum of products with diverse properties, and are used alone or as components of apparel, home furnishings, health care, engineering, industrial and consumer goods.
- nonwoven materials starts with the arrangement of fibres into a web.
- Examples of nonwovens produced by different techniques are wetlaid, airlaid, carded, spunlaid and airlay nonwovens.
- Webs may have a limited initial strength right after web formation and often need to be consolidated, by applying a binder to the web, by thermal treatment or by mechanical treatment. Further diversity can be added to nonwoven materials by a range of finishing treatments.
- the principle for producing wetlaid nonwovens is similar to paper manufacturing.
- a dilute slurry of water and fibres is deposited on a moving wire screen, where the water is drained, and the fibres form a web.
- the web is further dewatered by pressing between rollers and dried.
- a binder is usually included during the process, using for example size press, spraying or addition to the paper slurry process to increase the strength of the nonwoven material.
- a continuous web of fibres is formed using air as medium.
- fibres are dispersed in an air stream and deposited on for instance a moving wire.
- the resulting deposit is then compressed, for instance by pressure or vacuum.
- the material is at this stage totally unbonded since it cannot build up an internal strength as for example wetlaid nonwoven or paper can due to the hydrogen bonds formed in a wet process.
- a binder is usually added and may be introduced at different stages in the manufacturing process depending on the type of binder used.
- carded nonwovens are a drylaid nonwoven process, i.e. dry fibres are blended, after which they are conveyed to a moving wire. They are then combed into a web by a carding machine, which is a rotating drum or series of drums covered by card wire (thin strips with teeth).
- a carding machine which is a rotating drum or series of drums covered by card wire (thin strips with teeth).
- card wire strip with teeth.
- the precise configuration of cards will depend on the type of fibre and the basis weight to be produced.
- Fibre bonding of carded nonwovens often involve hydroentanglement of the fibres with waterjets with high pressure (spunlacing). Binders are also often added to the carded nonwoven material, in order to improve strength and/or other properties.
- binders to different nonwoven materials improves the strength of the material, but it can also provide or improve other properties, like softness, flexibility, water repellence or antibacterial properties, that are desired in a particular nonwoven material or application.
- the properties desired for a particular nonwoven material or in a particular application of a nonwoven material can be further tuned by adapting the add on, i.e. the level of application, of the binder composition.
- One example of a desired property is softness in airlaid nonwoven materials used in the manufacturing of different hygiene products like disposable diapers, feminine hygiene articles, industrial or consumer wipes, wet wipes and napkins.
- Hygiene products are usually characterized by their bulkiness, softness and high water absorption. Elongation is a key requirement for these soft airlaid nonwoven materials. If too stiff, i.e. not flexible with a soft hand feel, the airlaid nonwoven will be perceived as unpleasant to the user. Elongation is also crucial during production of the airlaid nonwoven material and in the converting step to the final product (e.g.
- One example of a desired property of the binder composition itself is a good applicability of the binder to different nonwoven materials. Carded nonwoven materials are relatively dense and it can be challenging to achieve a satisfying application of a binder in a carded nonwoven material.
- One alternative for applying a binder in more challenging materials is to use foam impregnation. This requires that the binder is readily foamable with common foaming agents.
- chitosan as a binder component in nonwoven materials has been examined before, such as in WO2012015863A1 .
- chitosan as the sole binder is not able to provide sufficiently good levels of mechanical properties such as for instance tensile strength. Therefore, a synthetic component, i.e. vinyl acetate ethylene, is provided in order to improve these properties as well as strength and elongation properties.
- Bio-based polyelectrolyte complexes have also been studied as an environmentally friendly binder alternative for materials such as fiber based materials, textiles, woven and nonwoven.
- PECs are association complexes formed between oppositely charged polycations and polyanions, formed due to electrostatic interaction between the oppositely charged polyions.
- Such a binder is for instance described in WO2018038671A1 .
- a nonwoven treated with a PEC binder composition will not work in for example an airlaid nonwoven requiring a high softness, as it only shows an elongation, i.e. elongation at break, of around 3%. An elongation of around 5 - 9 % is normally required for such applications.
- An object of the present invention is to provide a biobased binder composition suitable as a binder for a nonwoven material.
- An object of the present invention is to provide a biobased binder composition that is adaptable for treatment of different types of nonwoven materials.
- a further object of the invention is to provide a biobased binder composition that provides excellent mechanical properties to different types of treated nonwoven material.
- a further object of the invention is to provide a biobased binder composition that provides further properties to a treated nonwoven material.
- a further object of the invention is to provide a biobased binder composition which gives sufficiently high elongation to a treated nonwoven material.
- a further object of the invention is to provide a biobased binder composition which gives sufficiently high elongation to a treated airlaid nonwoven material.
- a further object of the invention is to provide an airlaid nonwoven material which exhibits strength and sufficiently good elongation, preferably an elongation of at least 4 %.
- a further object of the invention is to provide a biobased binder composition that is easily applicable to different nonwoven materials.
- a further object of the invention is to provide a biobased binder composition that provides excellent strength to a treated carded nonwoven material.
- a further object of the invention is to provide a biobased binder composition that is environmentally friendly, renewable, compostable and/or biodegradable.
- the invention in a first general aspect, relates to an aqueous biobased binder composition for a nonwoven material, said composition comprising an acid, a plasticizer and a cationic polyelectrolyte comprising chitosan, and wherein;
- the chitosan has a degree of deacetylation of 66 - 100%, and wherein the composition comprises 0.005 - 20 wt% of chitosan,
- the acid in the aqueous binder composition is a Bronsted acid and/or a Lewis acid, wherein the Bronsted acid is selected from any organic and/or inorganic acids, wherein the Lewis acid is selected from any cationic mono- or multivalent atom, and wherein the aqueous binder composition comprises preferably 0.01 - 30 wt% of acid,
- the aqueous binder composition comprises at least 0.5 wt% and less than 15 wt% of plasticizer, said plasticizer being a linear polyol selected from one or more of mannitol, maltitol, xylitol, and sorbitol and/or a saccharide being a non- macrocyclic saccharide selected from one or more of glucose, mannose, fructose, sucrose, sucralose, sucrose esters, hydrolysed starch or dextrin,
- the pH of the aqueous binder composition is less than 7, and wherein the cationic polyelectrolyte is not in a complex with an anionic polyelectrolyte.
- a binder for a nonwoven material comprising a high amount, or completely made of, renewable materials is achieved.
- a binder composition according to the present disclosure has been found to provide excellent mechanical properties in wetlaid, as well as in airlaid and carded nonwoven materials.
- macrocyclic is meant a cyclic macromolecular or a macromolecular cyclic portion of a macromolecule.
- macrocyclic compounds are cyclodextrins.
- the plasticizer is selected from a linear polyol and/or a non-macrocyclic saccharide. Without being bound to theory, such plasticizers are more flexible in their structure, thus resulting in a softer nonwoven material and a more efficient application within the nonwoven material fibre structure.
- a plasticizer being macrocyclic would result in a stiffer material.
- macrocyclic compounds have a tendency to exhibit increased hydrophobic character which can be undesired in certain nonwoven applications.
- the linear polyol is selected from one or more of mannitol, maltitol, xylitol and sorbitol.
- the saccharide being a non-macrocyclic saccharide is selected from one or more of glucose, mannose, fructose, sucrose, sucralose, sucrose esters, hydrolysed starch or dextrin.
- hydrolysed starch is a product from chemical or enzymatic treatment of starch from various natural sources.
- the hydrolysed starch can be hydrogenated and comprise a mixture of polyols .
- the hydrolysed starch is a source of sorbitol.
- an aqueous binder composition according to the present invention is able to act as a binder in an airlaid nonwoven material, resulting in a material exhibiting both sufficiently high strength and elongation, compared to conventional synthetic binders used by the industry.
- Chitosan compared to other cationic polyelectrolytes, imparts higher dry and especially wet tensile index to a material treated with the binder composition.
- the binder composition comprises at least 50 wt% of biobased, i.e. of natural origin, components, more preferably at least 60 wt%, more preferably at least 70 wt%, even more preferably at least 80 wt% and most preferably at least 90 wt%.
- a binder composition according to the present disclosure comprising chitosan (cationic polyelectrolyte) without the presence of an anionic counter ion in the composition, can provide a better flexibility and softness to nonwoven materials, compared to a binder composition comprising polyelectrolyte complexes comprising cations and anions.
- a cationic polyelectrolyte comprising chitosan, and substantially free from an anionic polyelectrolyte counter ion in the composition, is able to better spread within the nonwoven material, thus resulting in a more homogenous distribution.
- the cationic polyelectrolyte is able to better spread within the nonwoven structure. This results in a stronger and more flexible nonwoven material, compared to if a PEC binder composition was used, as the chitosan will act as a binding component linking with itself as well as with fibres within the airlaid nonwoven material.
- the synergistic effect between the cationic polyelectrolyte comprising chitosan and the plasticizer results in a composition suitable as a binder for nonwovens that is able to achieve both strength as well as elongation of a treated material comparable to conventional synthetic binders used.
- the aqueous binder composition is substantially free from anionic polyelectrolyte. If a substantial amount of an anionic polyelectrolyte would be present in the composition, the cationic and anionic polyelectrolyte would form a polyelectrolyte complex (PEC), resulting in an impaired functionality of the binder composition as previously described.
- PEC polyelectrolyte complex
- the pH of the composition is lower than 6.5, preferably the pH of the composition is between 1.8 - 5.
- the aqueous binder composition may further comprise a solvent selected from distilled water, tap water and deionized water.
- the amount of each of the components of the aqueous biobased binder composition depends on the intended use of the composition and the required properties necessary for that use, such as for instance strength, softness, elongation, water repellence, absorbency, cushioning, insulation properties and/or filtration properties.
- the aqueous binder composition comprises 0.01 - 11 wt%, such as 0.01 - 8 wt%, 0.01 - 5 wt% or 0.01 - 2 wt% of acid.
- the aqueous binder composition comprises at least 0.05 wt% and less than 15 wt% of plasticizer. In one aspect, the aqueous binder composition comprises 0.05 - 14 wt% of plasticizer.
- the aqueous binder composition comprises 2 - 14 wt%, preferably 5 - 14 wt%, of plasticizer, preferably 5 - 10 wt%.
- the aqueous binder comprises at least 1 wt%, such as at least 2 wt%, and less than 15 wt% of plasticizer. In one aspect, the aqueous binder comprises 1 - 10 wt% of plasticizer.
- the cationic polyelectrolyte in the aqueous binder composition consists of chitosan.
- the aqueous binder composition comprises 0.005 - 10 wt% of chitosan, preferably 0.005 - 5 wt%, and even more preferably between 0.5 - 2.5 wt%. The wt% of chitosan is optimized based on the desired viscosity.
- the acid is selected from one or more of acetic acid, acetylsalicylic acid, adipic acid, benzenesulfonic acid, camphorsulfonic acid, citric acid, citric acid monohydrate, dihydroxy fumaric acid, formic acid, glycolic acid, glyoxylic acid, hydrochloric acid, lactic acid, malic acid, malonic acid, maleic acid, mandelic acid, oxalic acid, para-toluenesulfonic acid, phtalic acid, pyruvic acid, salicylic acid, sulfuric acid, tartaric acid and succinic acid, preferably lactic acid.
- the aqueous binder composition comprises chitosan as cationic polyelectrolyte, lactic acid as acid, and at least one of sorbitol, hydrolysed starch, xylitol and maltitol as plasticizer.
- the plasticizer comprises hydrolysed starch.
- the aqueous binder composition further comprises at least one or more of an additive selected from defoamer, foaming agent, wetting agent, coalescent agent, catalyst, surfactant, emulsifier, preservative, rheology modifiers, fillers, nonionic polymers, dye and pigment, wherein the concentration of the additive is 0-50 wt% by weight more preferably 0-30% by weight of the total weight of the composition. Said additives are selected depending on application method and expected final material properties.
- the binder composition according to the present disclosure is easily applicable to different nonwoven materials, such as wetlaid, airlaid and carded nonwovens.
- foam impregnation is a suitable and energy efficient alternative for application of a binder.
- the binder is readily foamable with common foaming agents.
- the binder composition according to the present disclosure has proven to be easily foamable with common foaming agent and easy to apply to carded nonwovens by foam impregnation.
- treatment of carded nonwoven materials with a composition according to the present disclosure can provide carded nonwoven materials with excellent strength, derived from an efficient application of the binder to the material with foam impregnation.
- the aqueous binder composition comprises at least one foaming agent selected from one or more of an anionic surfactant, a cationic surfactant, a nonionic surfactant, and an amphoteric surfactant.
- the catalyst can be chosen from Lewis bases and acids, such as clays, colloidal or noncolloidal silica, dialdehydes, organic amines, organic amides, quaternary amines, metal oxides, metal sulphates, metal chlorides, urea sulphates, urea chlorides and catalysts based on silicates.
- Lewis bases and acids such as clays, colloidal or noncolloidal silica, dialdehydes, organic amines, organic amides, quaternary amines, metal oxides, metal sulphates, metal chlorides, urea sulphates, urea chlorides and catalysts based on silicates.
- the preservative can be selected from one or more of fungicide, bactericide, pharmaceutical preservative, cosmetic preservative and food preservatives.
- the inclusion of a preservative helps to inhibit the growth of mold in the binder composition.
- the filler may be selected from one or more of gum arabic, konjac glucomannan, organic fillers such as wood flour, starch soy flour, olive seed flour, cork flour, com cobs, rice brain husks, and inorganic fillers such as calcium carbonate, glass fibre, kaolin, talc and mice and other fillers known to the skilled person.
- organic fillers such as wood flour, starch soy flour, olive seed flour, cork flour, com cobs, rice brain husks
- inorganic fillers such as calcium carbonate, glass fibre, kaolin, talc and mice and other fillers known to the skilled person.
- the aqueous binder composition comprises 0.5 - 2.5 wt% of chitosan, at least 2 wt% and less than 15 wt% of plasticizer, 0.05 - 3 wt% of acid and optionally 0.05 - 10 wt% of at least one or more of an additive selected from a defoamer, a foaming agent, a wetting agent, a coalescent agent, a catalyst, a surfactant, an emulsifier, a conservative, a cross-linker, a rheology modifier, a filler, a nonionic polymer, a dye and a pigment.
- the plasticizer is present in an amount of 2 - 14 wt%.
- the present invention is directed to a method of treating a nonwoven material with a biobased binder composition, wherein the method comprises the steps of: a) providing a binder composition comprising an acid, a plasticizer and a cationic polyelectrolyte comprising chitosan, wherein the chitosan has a degree of deacetylation of 66 - 100%, the acid in the binder composition is a Bronsted acid and/or a Lewis acid, wherein the Bronsted acid is selected from any organic and/or inorganic acids, wherein the Lewis acid is selected from any cationic mono- or multivalent atom and wherein the cationic polyelectrolyte is not in a complex with an anionic polyelectrolyte; b) optionally, diluting the binder composition provided in step a); c) applying the composition of step a) or step b) to a nonwoven material by applying the binder composition on a formed nonwoven
- the biobased binder composition applied may be any biobased binder composition according to the first aspect.
- the nonwoven material treated according to the method disclosed in the present invention is selected from one or more of an airlaid nonwoven material, a wetlaid nonwoven material and a carded nonwoven material.
- the nonwoven material is substantially based on natural fibres such as wood fibres (e.g. pulp), fluff pulp, hemp fibres, or man-made biobased fibres such as viscose, lyocell and PLA.
- wood fibres e.g. pulp
- fluff pulp e.g. fluff pulp
- hemp fibres e.g. fluff pulp
- man-made biobased fibres such as viscose, lyocell and PLA.
- a nonwoven material is achieved exhibiting improved strength and elongation properties comparable to nonwovens bonded with conventional synthetic binders. This enables the substitution of conventional synthetic binders with a more environmentally friendly biobased alternative, without impairing the mechanical properties of the nonwoven material.
- the binder composition in step b) is diluted to an aqueous binder composition comprising 0.5 - 2.5 wt% of chitosan, at least 2 wt% and less than 15 wt% of plasticizer, 0.05 - 3 wt% of acid and optionally 0.05 - 10 wt% of at least one or more of an additive selected from defoamer, foaming agent, wetting agent, coalescent agent, catalyst, surfactant, emulsifier, conservative, cross-linker, rheology modifiers, fillers, nonionic polymers, dye and pigment.
- the binder composition is diluted so that the composition comprises 2 - 14 wt% plasticizer.
- the binder composition can be applied by for instance spraying the binder composition on the nonwoven material, or by coating the binder composition on the nonwoven material, or by impregnating the binder composition on the nonwoven material or by foam-impregnating the binder composition on the nonwoven material.
- the curing is performed at 20 to 200 degrees C.
- the curing is performed above 135 degrees C, preferably above 150 degrees C.
- the method results in higher elongation of the treated nonwoven, preferably the method results in an elongation of at least 4 %, preferably at least 5%.
- elongation means the total elongation at break measured according to standard Edana 20.2-89.
- the present invention is directed to a nonwoven material treated according to a method as defined in any of the previous aspects.
- the nonwoven material exhibits an elongation of at least 4% after the treatment with an aqueous binder composition as defined in any one of the previous aspects.
- the elongation is at least 5%. The elongation is measured according to Edana 20.2-89.
- the present invention is directed to use of an aqueous binder composition according to any one of the previous aspects for treating a nonwoven material.
- the use of the aqueous composition is preferably for providing excellent mechanical properties as well as other preferred properties to different kinds of nonwoven materials.
- wt% refers to weight percent of the ingredient, or ingredients, based on the total weight of the compound or composition.
- “about” refers to a measurable value, such as an amount, meant to encompass variations of +/-5% or less, even more preferably +/- 1 % or less, and still more preferably +/-0.1% or less of and from the specified value, in so far the skilled person understands that such variations are appropriate to perform in the disclosed invention. However, it is to be understood that the value to which “about” refers to is itself also specifically disclosed.
- a wetlaid nonwoven material is a nonwoven material produced by a wetlaid process.
- the wetlaid nonwoven can be produced with natural fibres such as wood fibres (e.g. pulp), fluff pulp, or hemp fibres, or manmade biobased fibres such as viscose, lyocell, PLA etc.
- natural fibres such as wood fibres (e.g. pulp), fluff pulp, or hemp fibres, or manmade biobased fibres such as viscose, lyocell, PLA etc.
- a small or substantial amount of synthetic fibres such as PES, PET, PP etc. and also inorganic fibres such as glass fibres, can also be present in the wetlaid nonwoven material.
- the wetlaid nonwoven material can be used in, but are not limited to, applications such as tabletop products such as napkins, tablets or tablecloths, wipes and wet wipes, hygiene products such as diapers or femine hygiene products, agricultural nonwovens such as mulch films, air filtration materials, tea bags, coffee filters, food pads, geotextiles, and wallpapers.
- an airlaid nonwoven material is a nonwoven material produced by an airlaid (dry laid) process.
- the airlaid nonwoven can be produced by natural fibres such as wood fibres (e.g. pulp), fluff pulp, or hemp fibres or manmade biobased fibres such as viscose, lyocell, PLA etc.
- natural fibres such as wood fibres (e.g. pulp), fluff pulp, or hemp fibres or manmade biobased fibres such as viscose, lyocell, PLA etc.
- a small or substantial amount of synthetic fibres such as PES, PET, PP etc. can also be present in the airlaid nonwoven material.
- the airlaid nonwoven material can be used in, but are not limited to, applications such as hygiene applications such as baby diapers, feminine hygiene products, and adultery care products; tabletop products such as napkins or tablets, tablecloths; filter materials; automotive nonwovens; tea bags and coffee filters; medical nonwovens used for face masks, surgical gowns and hair covers; food packaging materials and food pads; wipes and wet wipes; and geotextiles.
- applications such as hygiene applications such as baby diapers, feminine hygiene products, and adultery care products; tabletop products such as napkins or tablets, tablecloths; filter materials; automotive nonwovens; tea bags and coffee filters; medical nonwovens used for face masks, surgical gowns and hair covers; food packaging materials and food pads; wipes and wet wipes; and geotextiles.
- a carded nonwoven material is a nonwoven material produced by a carding process.
- the carded nonwoven can be produced by natural fibres such as wood fibres (e.g. pulp), fluff pulp, or hemp fibres or man-made biobased fibres such as viscose, lyocell, PLA etc.
- natural fibres such as wood fibres (e.g. pulp), fluff pulp, or hemp fibres or man-made biobased fibres such as viscose, lyocell, PLA etc.
- a small or substantial amount of synthetic fibres such as PES, PET, PP etc. can also be present in the carded nonwoven material.
- the carded nonwoven material can be used in, but are not limited to, applications such as hygiene applications such as baby diapers, feminine hygiene products, and adultery care products; filter materials; automotive nonwovens; tea bags and coffee filters; medical nonwovens used for face masks, surgical gowns and hair covers; food packaging materials and food pads; wipes and wet wipes; geotextiles; building materials for insulation and roofing; carpets, wallpapers, mattresses, and agricultural nonwovens.
- applications such as hygiene applications such as baby diapers, feminine hygiene products, and adultery care products; filter materials; automotive nonwovens; tea bags and coffee filters; medical nonwovens used for face masks, surgical gowns and hair covers; food packaging materials and food pads; wipes and wet wipes; geotextiles; building materials for insulation and roofing; carpets, wallpapers, mattresses, and agricultural nonwovens.
- a surfactant is a molecule comprising a hydrophilic “head” and a hydrophobic “tail”.
- a polyelectrolyte is a polymer whose repeating units bear a charged group.
- Example 1 Application of Binder A on wetlaid nonwoven material by spraying
- a wetlaid material of unbonded cellulosic mixed fibres was used as substrate.
- the material was added on top of a conveyor belt running in different speeds (3, 5 and 7 m/min).
- Binder A was diluted from a dry weight of 26 wt% (measured with a moisture analyzer from VWR) to a dry weight of 2.5 wt% and sprayed on the wetlaid nonwoven material.
- the wetlaid nonwoven material was then cured, by passing through an oven that was 2 m long and heated to 160 °C After the treatment, the material was acclimatized overnight in 23 °C and 50 % RH.
- Tensile testing was then performed on cut-out samples of 50 mm by 250 mm using a Testometric M250-2.5AT tensile testing machine. Seven specimen per trial was measured. Both a dry tensile test and a wet tensile test were performed. As a comparison, dry and wet tensile testing was performed on wetlaid nonwoven material without applied binder. For the wet tensile test, a Finish cup was used where the specimen was submerged in water for 15 s. Results from the dry tensile test can be found in Table 2 and from the wet tensile test in Table 3. All values are mean values.
- Test no 1 refers to the material without binder.
- Test no 1 refers to the material without binder.
- the binder increases the mechanical properties of wetlaid nonwoven materials in both wet and dry conditions.
- the increase in tensile index required for a specific application can easily be tuned by adapting the add on of the binder composition.
- Binder B was diluted from a dry weight of 27 wt% (measured with a moisture analyser from VWR) to a dry weight of 14wt% and added between two compressed rolls of a horizontal padder from Wichelhaus GmbH. The speed of the rolls was set to 11 .6 m/min and the pressure between the rolls to 0.1 MPa.
- the material used in this study was airlaid nonwoven (fluff pulp fibers) and wetlaid nonwoven (mixed cellulosic fibers). After the impregnation, the material was put on a conveyer belt with the speed of 5 m/min which passed through a 3 m long oven heated to 160 °C. The material was acclimatized overnight in 23 °C and 50 %.
- Tensile testing was then performed on cut-out samples of 50 mm by 250 mm using a Testometric M250-2.5AT tensile testing machine. As a comparison, tensile testing was performed also on wetlaid and airlaid nonwoven material without applied binder. Ten specimen per trial were measured and the results from the tensile test can be found in Table 4. All values are mean values.
- Example 3 Foamability of Binder A with two different foaming agents.
- Binder A The foamability of Binder A with two different foaming agents was evaluated.
- a nonionic foaming agent Glucopone 215 UP
- a zwitterionic foaming agent Ammonyx LO
- Binder A was diluted from a dry weight of 26 wt% (measured with a moisture analyser from VWR) to a dry weight of 14 wt%. 100 g of the dilution of Binder A and 1 g of the respective foaming agent were added to a 250 ml beaker. The mixture was mixed with a propeller at 1500 rpm for 5 min. The height of the foam phase was measured directly after mixing and 5 minutes after finishing of the mixing. The results are shown in Table 5 below.
- Binder A was foamable with both the tested foaming agents and that the foams keep stable for at least 5 minutes, which allows for a smooth application of the binder with foam impregnation.
- Binder A was diluted from a dry weight of 26 wt% (measured with a moisture analyser from VWR) a dry weight of 10%. To 200 g of the dilution, 1 .67 g Glucopon 215 UP (foaming agent, nonionic surfactant) was added, and the mixture was stirred vigorously at 2000 rpm with a disperser assembled on an overhead stirrer from IKA Werke for 60 s. A dense and stable foam was observed. The foam was added between two compressed rolls of a horizontal padder from Wichelhaus GmbH. The speed of the rolls was set to 11.6 m/min and the pressure between the rolls to 0.1 MPa. A carded viscose nonwoven was passed through the rolls.
- the nonwoven material was then dried in an oven from Termaks set at 170 °C for 3 min. The material was acclimatized overnight in 23 °C and 50 %RH. Tensile testing was then performed on cut-out samples of 50 mm by 250 mm using a Testometric M250-2.5AT tensile testing machine. As a comparison, tensile testing was performed also on carded nonwoven material without applied binder. Eight specimen per trial was measured and the results from the tensile test can be found in Table 6. All values are mean values.
- the carded viscose nonwoven is in itself very elastic due to the long staple fibres that are building up the material.
- a stiffer, yet stronger, material can be achieved, which is clearly illustrated by the increase in tensile stiffness index in the carded nonwoven material treated with the foamed binder composition.
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- General Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Nonwoven Fabrics (AREA)
Abstract
The present invention relates to biobased binder compositions which are environmentally benign, renewable, compostable and/or biodegradable. The biobased compositions comprise chitosan, an acid and a plasticizer. By treating a nonwoven material with a biobased binder according to the present invention, it is possible to provide a nonwoven material exhibiting excellent mechanical properties. The binder composition according to the present invention is easy to use for treatment of different types of nonwoven materials and can be adapted to provide specific properties to certain nonwoven materials and applications.
Description
BIOBASED BINDER COMPOSITIONS FOR NONWOVEN MATERIALS
Technical field
[0001] The present invention relates to biobased binder compositions which are environmentally benign, renewable, compostable and/or biodegradable. The biobased compositions comprise chitosan, an acid and a plasticizer being a linear polyol and/or a non-macrocyclic saccharide. The invention further relates to a method of treating a nonwoven material with a biobased binder composition according to the present invention.
[0002] The compositions according to the present invention are suitable as a binder for different types of nonwoven materials. The treatment of various nonwoven materials with a binder composition according to the present invention provides nonwoven materials with excellent mechanical properties. In addition, the binder composition according to the present invention is easy to use for treatment of different types of nonwoven materials and can be adapted to provide specific properties to certain nonwoven materials and applications.
Background art
[0003] Nonwoven materials are fabric-like materials made from long or short fibres, bonded together by a chemical, a mechanical, a heat or a solvent treatment. Nonwoven fabrics are also defined as sheet or web structures bonded together by entangling fiber or filaments (and by perforating films) mechanically, thermally or chemically. The term is used in the textile manufacturing industry to denote fabrics, such as felt, which are neither woven nor knitted. They are flat or tufted porous sheets that are made directly from separate fibres, molten plastic or plastic film.
[0004] Nonwoven materials can provide specific functions such as absorbency, water repellence, softness, strength, flame retardancy, cushioning, thermal insulation, acoustic insulation, filtration, bacterial barrier and sterility. These properties are often combined to create fabrics suited for specific applications, while achieving a good balance between product use-life and cost. They can
mimic the appearance, texture and strength of a woven fabric and can be as bulky as a thick padding. In combination with other materials, they provide a spectrum of products with diverse properties, and are used alone or as components of apparel, home furnishings, health care, engineering, industrial and consumer goods.
[0005] Production of nonwoven materials starts with the arrangement of fibres into a web. There are different techniques for arranging the fibres, resulting in nonwoven materials with different properties, suitable for different applications. Examples of nonwovens produced by different techniques are wetlaid, airlaid, carded, spunlaid and airlay nonwovens. Webs may have a limited initial strength right after web formation and often need to be consolidated, by applying a binder to the web, by thermal treatment or by mechanical treatment. Further diversity can be added to nonwoven materials by a range of finishing treatments.
[0006] The principle for producing wetlaid nonwovens is similar to paper manufacturing. A dilute slurry of water and fibres is deposited on a moving wire screen, where the water is drained, and the fibres form a web. The web is further dewatered by pressing between rollers and dried. A binder is usually included during the process, using for example size press, spraying or addition to the paper slurry process to increase the strength of the nonwoven material.
[0007] In the airlaid process, a continuous web of fibres is formed using air as medium. Generally, fibres are dispersed in an air stream and deposited on for instance a moving wire. The resulting deposit is then compressed, for instance by pressure or vacuum. However, the material is at this stage totally unbonded since it cannot build up an internal strength as for example wetlaid nonwoven or paper can due to the hydrogen bonds formed in a wet process. In order to achieve bonding or other mechanical improvements in airlaid nonwovens, a binder is usually added and may be introduced at different stages in the manufacturing process depending on the type of binder used.
[0008] The production of carded nonwovens is a drylaid nonwoven process, i.e. dry fibres are blended, after which they are conveyed to a moving wire. They are then combed into a web by a carding machine, which is a rotating drum or series
of drums covered by card wire (thin strips with teeth). The precise configuration of cards will depend on the type of fibre and the basis weight to be produced. Fibre bonding of carded nonwovens often involve hydroentanglement of the fibres with waterjets with high pressure (spunlacing). Binders are also often added to the carded nonwoven material, in order to improve strength and/or other properties.
[0009] Traditionally, both liquid binders, slurries, suspensions, foams or powder binders have been used in the manufacturing of nonwoven materials. The most common bonding technique is the addition of a liquid binder to the nonwoven material, applied by, for example, impregnation, coating or spraying.
[0010] The addition of binders to different nonwoven materials improves the strength of the material, but it can also provide or improve other properties, like softness, flexibility, water repellence or antibacterial properties, that are desired in a particular nonwoven material or application.
[0011 ] The properties desired for a particular nonwoven material or in a particular application of a nonwoven material can be further tuned by adapting the add on, i.e. the level of application, of the binder composition.
[0012] One example of a desired property is softness in airlaid nonwoven materials used in the manufacturing of different hygiene products like disposable diapers, feminine hygiene articles, industrial or consumer wipes, wet wipes and napkins. Hygiene products are usually characterized by their bulkiness, softness and high water absorption. Elongation is a key requirement for these soft airlaid nonwoven materials. If too stiff, i.e. not flexible with a soft hand feel, the airlaid nonwoven will be perceived as unpleasant to the user. Elongation is also crucial during production of the airlaid nonwoven material and in the converting step to the final product (e.g. converting airlaid nonwoven to a napkin) as the machines induce high tensions in the material which require the material to have a high elongation in order not to break. Moreover, if the airlaid nonwoven material is not sufficiently strong and flexible, the material might break apart when used. To combine strength, soft hand feel and elongation is thus of crucial importance when developing airlaid nonwoven materials for these applications. Treatment of airlaid
nonwoven materials with a composition according to the present disclosure will provide airlaid nonwoven materials which have the required softness, strength and elongation.
[0013] One example of a desired property of the binder composition itself is a good applicability of the binder to different nonwoven materials. Carded nonwoven materials are relatively dense and it can be challenging to achieve a satisfying application of a binder in a carded nonwoven material. One alternative for applying a binder in more challenging materials is to use foam impregnation. This requires that the binder is readily foamable with common foaming agents.
[0014] In an attempt to reduce the usage of synthetic binders, i.e. plastic binders, attention has been drawn to biobased polymers that can substitute the synthetic polymers used for nonwovens. Nevertheless, none of the alternatives so far can achieve a nonwoven article with such excellent mechanical properties in different kinds of nonwoven materials, while at the same time being so adaptable to provide the properties needed in a particular type of nonwoven material or application.
[0015] Previous attempts have been made to reduce or eliminate the usage of synthetic binders in nonwovens, such as in W02020068151A1 . However, the article disclosed in W02020068151 A1 still comprises synthetic fibres and/or wet strength agents.
[0016] The use of chitosan as a binder component in nonwoven materials has been examined before, such as in WO2012015863A1 . However, as clearly stated in WO2012015863A1 , chitosan as the sole binder is not able to provide sufficiently good levels of mechanical properties such as for instance tensile strength. Therefore, a synthetic component, i.e. vinyl acetate ethylene, is provided in order to improve these properties as well as strength and elongation properties.
[0017] Bio-based polyelectrolyte complexes (PEC) have also been studied as an environmentally friendly binder alternative for materials such as fiber based materials, textiles, woven and nonwoven. PECs are association complexes formed
between oppositely charged polycations and polyanions, formed due to electrostatic interaction between the oppositely charged polyions. Such a binder is for instance described in WO2018038671A1 . However, a nonwoven treated with a PEC binder composition will not work in for example an airlaid nonwoven requiring a high softness, as it only shows an elongation, i.e. elongation at break, of around 3%. An elongation of around 5 - 9 % is normally required for such applications.
[0018] There is thus still a need for a biobased binder composition suitable for use with different nonwoven materials and for different applications, providing excellent mechanical properties to the materials and also providing other properties required in a particular nonwoven material or application.
Summary of invention
[0019] An object of the present invention is to provide a biobased binder composition suitable as a binder for a nonwoven material.
[0020] An object of the present invention is to provide a biobased binder composition that is adaptable for treatment of different types of nonwoven materials.
[0021 ] A further object of the invention is to provide a biobased binder composition that provides excellent mechanical properties to different types of treated nonwoven material.
[0022] A further object of the invention is to provide a biobased binder composition that provides further properties to a treated nonwoven material.
[0023] A further object of the invention is to provide a biobased binder composition which gives sufficiently high elongation to a treated nonwoven material.
[0024] A further object of the invention is to provide a biobased binder composition which gives sufficiently high elongation to a treated airlaid nonwoven material.
[0025] A further object of the invention is to provide an airlaid nonwoven material which exhibits strength and sufficiently good elongation, preferably an elongation of at least 4 %.
[0026] A further object of the invention is to provide a biobased binder composition that is easily applicable to different nonwoven materials.
[0027] A further object of the invention is to provide a biobased binder composition that provides excellent strength to a treated carded nonwoven material.
[0028] A further object of the invention is to provide a biobased binder composition that is environmentally friendly, renewable, compostable and/or biodegradable.
[0029] Any combination of the above objects is also possible.
[0030] In a first general aspect, the invention relates to an aqueous biobased binder composition for a nonwoven material, said composition comprising an acid, a plasticizer and a cationic polyelectrolyte comprising chitosan, and wherein;
- the chitosan has a degree of deacetylation of 66 - 100%, and wherein the composition comprises 0.005 - 20 wt% of chitosan,
- the acid in the aqueous binder composition is a Bronsted acid and/or a Lewis acid, wherein the Bronsted acid is selected from any organic and/or inorganic acids, wherein the Lewis acid is selected from any cationic mono- or multivalent atom, and wherein the aqueous binder composition comprises preferably 0.01 - 30 wt% of acid,
- the aqueous binder composition comprises at least 0.5 wt% and less than 15 wt% of plasticizer, said plasticizer being a linear polyol selected from one or more of mannitol, maltitol, xylitol, and sorbitol and/or a saccharide being a non- macrocyclic saccharide selected from one or more of glucose, mannose, fructose, sucrose, sucralose, sucrose esters, hydrolysed starch or dextrin,
- the pH of the aqueous binder composition is less than 7,
and wherein the cationic polyelectrolyte is not in a complex with an anionic polyelectrolyte.
[0031] With an aqueous biobased binder composition according to the present disclosure, a binder for a nonwoven material comprising a high amount, or completely made of, renewable materials is achieved. A binder composition according to the present disclosure has been found to provide excellent mechanical properties in wetlaid, as well as in airlaid and carded nonwoven materials.
[0032] According to lUPAC-standard, by “macrocyclic” is meant a cyclic macromolecular or a macromolecular cyclic portion of a macromolecule. Examples of macrocyclic compounds are cyclodextrins.
[0033] The plasticizer is selected from a linear polyol and/or a non-macrocyclic saccharide. Without being bound to theory, such plasticizers are more flexible in their structure, thus resulting in a softer nonwoven material and a more efficient application within the nonwoven material fibre structure. A plasticizer being macrocyclic would result in a stiffer material. Moreover, macrocyclic compounds have a tendency to exhibit increased hydrophobic character which can be undesired in certain nonwoven applications.
[0034] The linear polyol is selected from one or more of mannitol, maltitol, xylitol and sorbitol. The saccharide being a non-macrocyclic saccharide is selected from one or more of glucose, mannose, fructose, sucrose, sucralose, sucrose esters, hydrolysed starch or dextrin.
[0035] In the context of the plasticizer, hydrolysed starch is a product from chemical or enzymatic treatment of starch from various natural sources. The hydrolysed starch can be hydrogenated and comprise a mixture of polyols . The hydrolysed starch is a source of sorbitol.
[0036] Furthermore, it has surprisingly been found that an aqueous binder composition according to the present invention is able to act as a binder in an airlaid nonwoven material, resulting in a material exhibiting both sufficiently high
strength and elongation, compared to conventional synthetic binders used by the industry. Chitosan, compared to other cationic polyelectrolytes, imparts higher dry and especially wet tensile index to a material treated with the binder composition. Preferably, the binder composition comprises at least 50 wt% of biobased, i.e. of natural origin, components, more preferably at least 60 wt%, more preferably at least 70 wt%, even more preferably at least 80 wt% and most preferably at least 90 wt%.
[0037] Experiments have shown that a binder composition according to the present disclosure, comprising chitosan (cationic polyelectrolyte) without the presence of an anionic counter ion in the composition, can provide a better flexibility and softness to nonwoven materials, compared to a binder composition comprising polyelectrolyte complexes comprising cations and anions.
[0038] It has been found that in a binder composition according to the present disclosure, a cationic polyelectrolyte comprising chitosan, and substantially free from an anionic polyelectrolyte counter ion in the composition, is able to better spread within the nonwoven material, thus resulting in a more homogenous distribution. Without being bound by theory, it is believed that the lack of an electrostatic interaction between the cationic polyelectrolyte and an anionic polyelectrolyte, results in a cationic polyelectrolyte in a more expanded shape. If the cationic polyelectrolyte was to interact with an anionic counter component, the resulting polyelectrolyte complex would exhibit a more coiled structure. By achieving a more expanded shape, it is believed that the cationic polyelectrolyte is able to better spread within the nonwoven structure. This results in a stronger and more flexible nonwoven material, compared to if a PEC binder composition was used, as the chitosan will act as a binding component linking with itself as well as with fibres within the airlaid nonwoven material. The synergistic effect between the cationic polyelectrolyte comprising chitosan and the plasticizer results in a composition suitable as a binder for nonwovens that is able to achieve both strength as well as elongation of a treated material comparable to conventional synthetic binders used.
[0039] In one aspect, the aqueous binder composition is substantially free from anionic polyelectrolyte. If a substantial amount of an anionic polyelectrolyte would be present in the composition, the cationic and anionic polyelectrolyte would form a polyelectrolyte complex (PEC), resulting in an impaired functionality of the binder composition as previously described.
[0040] It is important that the pH is below 7 in the aqueous binder composition, as an acidic environment is needed for the chitosan to be in its cationic form.
Preferably, the pH of the composition is lower than 6.5, preferably the pH of the composition is between 1.8 - 5.
[0041 ] In one aspect, the aqueous binder composition may further comprise a solvent selected from distilled water, tap water and deionized water.
[0042] The amount of each of the components of the aqueous biobased binder composition depends on the intended use of the composition and the required properties necessary for that use, such as for instance strength, softness, elongation, water repellence, absorbency, cushioning, insulation properties and/or filtration properties.
[0043] In one aspect, the aqueous binder composition comprises 0.01 - 11 wt%, such as 0.01 - 8 wt%, 0.01 - 5 wt% or 0.01 - 2 wt% of acid.
[0044] In one aspect, the aqueous binder composition comprises at least 0.05 wt% and less than 15 wt% of plasticizer. In one aspect, the aqueous binder composition comprises 0.05 - 14 wt% of plasticizer.
[0045] In one aspect, the aqueous binder composition comprises 2 - 14 wt%, preferably 5 - 14 wt%, of plasticizer, preferably 5 - 10 wt%.
[0046] In one aspect, the aqueous binder comprises at least 1 wt%, such as at least 2 wt%, and less than 15 wt% of plasticizer. In one aspect, the aqueous binder comprises 1 - 10 wt% of plasticizer.
[0047] In one aspect, the cationic polyelectrolyte in the aqueous binder composition consists of chitosan.
[0048] In one aspect, the aqueous binder composition comprises 0.005 - 10 wt% of chitosan, preferably 0.005 - 5 wt%, and even more preferably between 0.5 - 2.5 wt%. The wt% of chitosan is optimized based on the desired viscosity.
[0049] In one aspect, the acid is selected from one or more of acetic acid, acetylsalicylic acid, adipic acid, benzenesulfonic acid, camphorsulfonic acid, citric acid, citric acid monohydrate, dihydroxy fumaric acid, formic acid, glycolic acid, glyoxylic acid, hydrochloric acid, lactic acid, malic acid, malonic acid, maleic acid, mandelic acid, oxalic acid, para-toluenesulfonic acid, phtalic acid, pyruvic acid, salicylic acid, sulfuric acid, tartaric acid and succinic acid, preferably lactic acid.
[0050] In one aspect, the aqueous binder composition comprises chitosan as cationic polyelectrolyte, lactic acid as acid, and at least one of sorbitol, hydrolysed starch, xylitol and maltitol as plasticizer. Preferably, the plasticizer comprises hydrolysed starch.
[0051] In one aspect, the aqueous binder composition further comprises at least one or more of an additive selected from defoamer, foaming agent, wetting agent, coalescent agent, catalyst, surfactant, emulsifier, preservative, rheology modifiers, fillers, nonionic polymers, dye and pigment, wherein the concentration of the additive is 0-50 wt% by weight more preferably 0-30% by weight of the total weight of the composition. Said additives are selected depending on application method and expected final material properties.
[0052] The binder composition according to the present disclosure is easily applicable to different nonwoven materials, such as wetlaid, airlaid and carded nonwovens. For carded nonwoven materials, being relatively dense, foam impregnation is a suitable and energy efficient alternative for application of a binder. This requires that the binder is readily foamable with common foaming agents. The binder composition according to the present disclosure has proven to be easily foamable with common foaming agent and easy to apply to carded nonwovens by foam impregnation. Hence, treatment of carded nonwoven materials with a composition according to the present disclosure can provide
carded nonwoven materials with excellent strength, derived from an efficient application of the binder to the material with foam impregnation.
[0053] In one aspect the aqueous binder composition comprises at least one foaming agent selected from one or more of an anionic surfactant, a cationic surfactant, a nonionic surfactant, and an amphoteric surfactant.
[0054] The catalyst can be chosen from Lewis bases and acids, such as clays, colloidal or noncolloidal silica, dialdehydes, organic amines, organic amides, quaternary amines, metal oxides, metal sulphates, metal chlorides, urea sulphates, urea chlorides and catalysts based on silicates.
[0055] The preservative can be selected from one or more of fungicide, bactericide, pharmaceutical preservative, cosmetic preservative and food preservatives. The inclusion of a preservative helps to inhibit the growth of mold in the binder composition.
[0056] The filler may be selected from one or more of gum arabic, konjac glucomannan, organic fillers such as wood flour, starch soy flour, olive seed flour, cork flour, com cobs, rice brain husks, and inorganic fillers such as calcium carbonate, glass fibre, kaolin, talc and mice and other fillers known to the skilled person.
[0057] In one aspect, the aqueous binder composition comprises 0.5 - 2.5 wt% of chitosan, at least 2 wt% and less than 15 wt% of plasticizer, 0.05 - 3 wt% of acid and optionally 0.05 - 10 wt% of at least one or more of an additive selected from a defoamer, a foaming agent, a wetting agent, a coalescent agent, a catalyst, a surfactant, an emulsifier, a conservative, a cross-linker, a rheology modifier, a filler, a nonionic polymer, a dye and a pigment. In one further aspect, the plasticizer is present in an amount of 2 - 14 wt%.
[0058] In a second general aspect, the present invention is directed to a method of treating a nonwoven material with a biobased binder composition, wherein the method comprises the steps of: a) providing a binder composition comprising an acid, a plasticizer and a cationic
polyelectrolyte comprising chitosan, wherein the chitosan has a degree of deacetylation of 66 - 100%, the acid in the binder composition is a Bronsted acid and/or a Lewis acid, wherein the Bronsted acid is selected from any organic and/or inorganic acids, wherein the Lewis acid is selected from any cationic mono- or multivalent atom and wherein the cationic polyelectrolyte is not in a complex with an anionic polyelectrolyte; b) optionally, diluting the binder composition provided in step a); c) applying the composition of step a) or step b) to a nonwoven material by applying the binder composition on a formed nonwoven web, wherein the applied composition is a composition comprising 0.005 - 20 wt% of chitosan, at least 0.5 wt% and less than 15 wt% of plasticizer, wherein said plasticizer being a linear polyol selected from one or more of glycerol, mannitol, maltitol, xylitol, and sorbitol and/or a saccharide being a non-macrocyclic saccharide selected from one or more of glucose, mannose, fructose, sucrose, sucralose, sucrose esters, hydrolysed starch or dextrin, 0.01 - 30 wt% of acid and optionally 0.05 - 10 wt% of at least one or more of an additive selected from a defoamer, a foaming agent, a wetting agent, a coalescent agent, a catalyst, a surfactant, an emulsifier, a preservative, a cross-linker, a rheology modifier, a filler, a nonionic polymer, a dye and a pigment; d) optionally curing the treated nonwoven material, preferably wherein the curing is performed at 20 to 200 degrees C.
[0059] The biobased binder composition applied may be any biobased binder composition according to the first aspect.
[0060] In one aspect, the nonwoven material treated according to the method disclosed in the present invention is selected from one or more of an airlaid nonwoven material, a wetlaid nonwoven material and a carded nonwoven material.
[0061] In one aspect, the nonwoven material is substantially based on natural fibres such as wood fibres (e.g. pulp), fluff pulp, hemp fibres, or man-made biobased fibres such as viscose, lyocell and PLA.
[0062] By using a method according to the present invention, a nonwoven material is achieved exhibiting improved strength and elongation properties comparable to nonwovens bonded with conventional synthetic binders. This enables the substitution of conventional synthetic binders with a more environmentally friendly biobased alternative, without impairing the mechanical properties of the nonwoven material.
[0063] In one aspect of the invention, the binder composition in step b) is diluted to an aqueous binder composition comprising 0.5 - 2.5 wt% of chitosan, at least 2 wt% and less than 15 wt% of plasticizer, 0.05 - 3 wt% of acid and optionally 0.05 - 10 wt% of at least one or more of an additive selected from defoamer, foaming agent, wetting agent, coalescent agent, catalyst, surfactant, emulsifier, conservative, cross-linker, rheology modifiers, fillers, nonionic polymers, dye and pigment. In one further aspect, the binder composition is diluted so that the composition comprises 2 - 14 wt% plasticizer.
[0064] The binder composition can be applied by for instance spraying the binder composition on the nonwoven material, or by coating the binder composition on the nonwoven material, or by impregnating the binder composition on the nonwoven material or by foam-impregnating the binder composition on the nonwoven material.
[0065] In one aspect, the curing is performed at 20 to 200 degrees C. Preferably, the curing is performed above 135 degrees C, preferably above 150 degrees C.
[0066] In one aspect, the method results in higher elongation of the treated nonwoven, preferably the method results in an elongation of at least 4 %, preferably at least 5%. As used herein, elongation means the total elongation at break measured according to standard Edana 20.2-89.
[0067] In third general aspect, the present invention is directed to a nonwoven material treated according to a method as defined in any of the previous aspects.
[0068] In one aspect, the nonwoven material exhibits an elongation of at least 4% after the treatment with an aqueous binder composition as defined in any one of the previous aspects. Preferably, the elongation is at least 5%. The elongation is measured according to Edana 20.2-89.
[0069] In another general aspect, the present invention is directed to use of an aqueous binder composition according to any one of the previous aspects for treating a nonwoven material. The use of the aqueous composition is preferably for providing excellent mechanical properties as well as other preferred properties to different kinds of nonwoven materials.
Description of embodiments
[0070] In the following, a detailed description of the present invention is provided.
[0071] As used herein, “wt%” refers to weight percent of the ingredient, or ingredients, based on the total weight of the compound or composition.
[0072] As used herein, “about” refers to a measurable value, such as an amount, meant to encompass variations of +/-5% or less, even more preferably +/- 1 % or less, and still more preferably +/-0.1% or less of and from the specified value, in so far the skilled person understands that such variations are appropriate to perform in the disclosed invention. However, it is to be understood that the value to which “about” refers to is itself also specifically disclosed.
[0073] As used herein, a wetlaid nonwoven material is a nonwoven material produced by a wetlaid process. The wetlaid nonwoven can be produced with natural fibres such as wood fibres (e.g. pulp), fluff pulp, or hemp fibres, or manmade biobased fibres such as viscose, lyocell, PLA etc. A small or substantial amount of synthetic fibres such as PES, PET, PP etc. and also inorganic fibres such as glass fibres, can also be present in the wetlaid nonwoven material. The wetlaid nonwoven material can be used in, but are not limited to, applications such as tabletop products such as napkins, tablets or tablecloths, wipes and wet wipes, hygiene products such as diapers or femine hygiene products, agricultural
nonwovens such as mulch films, air filtration materials, tea bags, coffee filters, food pads, geotextiles, and wallpapers.
[0074] As used herein, an airlaid nonwoven material is a nonwoven material produced by an airlaid (dry laid) process. The airlaid nonwoven can be produced by natural fibres such as wood fibres (e.g. pulp), fluff pulp, or hemp fibres or manmade biobased fibres such as viscose, lyocell, PLA etc. A small or substantial amount of synthetic fibres such as PES, PET, PP etc. can also be present in the airlaid nonwoven material. The airlaid nonwoven material can be used in, but are not limited to, applications such as hygiene applications such as baby diapers, feminine hygiene products, and adultery care products; tabletop products such as napkins or tablets, tablecloths; filter materials; automotive nonwovens; tea bags and coffee filters; medical nonwovens used for face masks, surgical gowns and hair covers; food packaging materials and food pads; wipes and wet wipes; and geotextiles.
[0075] As used herein, a carded nonwoven material is a nonwoven material produced by a carding process. The carded nonwoven can be produced by natural fibres such as wood fibres (e.g. pulp), fluff pulp, or hemp fibres or man-made biobased fibres such as viscose, lyocell, PLA etc. A small or substantial amount of synthetic fibres such as PES, PET, PP etc. can also be present in the carded nonwoven material. The carded nonwoven material can be used in, but are not limited to, applications such as hygiene applications such as baby diapers, feminine hygiene products, and adultery care products; filter materials; automotive nonwovens; tea bags and coffee filters; medical nonwovens used for face masks, surgical gowns and hair covers; food packaging materials and food pads; wipes and wet wipes; geotextiles; building materials for insulation and roofing; carpets, wallpapers, mattresses, and agricultural nonwovens.
[0076] As used herein, a surfactant is a molecule comprising a hydrophilic “head” and a hydrophobic “tail”.
[0077] As used herein a polyelectrolyte is a polymer whose repeating units bear a charged group.
[0078] The invention is further illustrated in the following examples, which do not limit the scope of the invention described in the claims.
Experimental section
Table 1. Binder compositions
[0079] Example 1 : Application of Binder A on wetlaid nonwoven material by spraying
[0080] A wetlaid material of unbonded cellulosic mixed fibres was used as substrate. The material was added on top of a conveyor belt running in different speeds (3, 5 and 7 m/min). Binder A was diluted from a dry weight of 26 wt% (measured with a moisture analyzer from VWR) to a dry weight of 2.5 wt% and sprayed on the wetlaid nonwoven material. The wetlaid nonwoven material was then cured, by passing through an oven that was 2 m long and heated to 160 °C
After the treatment, the material was acclimatized overnight in 23 °C and 50 % RH. Tensile testing was then performed on cut-out samples of 50 mm by 250 mm using a Testometric M250-2.5AT tensile testing machine. Seven specimen per trial was measured. Both a dry tensile test and a wet tensile test were performed. As a comparison, dry and wet tensile testing was performed on wetlaid nonwoven material without applied binder. For the wet tensile test, a Finish cup was used where the specimen was submerged in water for 15 s. Results from the dry tensile test can be found in Table 2 and from the wet tensile test in Table 3. All values are mean values.
Table 2. Dry tensile test. Test no 1 refers to the material without binder.
Table 3. Wet tensile test. Test no 1 refers to the material without binder.
[0081] From example 1 , it can be concluded that the binder increases the mechanical properties of wetlaid nonwoven materials in both wet and dry conditions. The increase in tensile index required for a specific application can easily be tuned by adapting the add on of the binder composition.
Example 2 - Application of Binder B on airlaid and wetlaid nonwoven material by impregnation
[0082] Binder B was diluted from a dry weight of 27 wt% (measured with a moisture analyser from VWR) to a dry weight of 14wt% and added between two compressed rolls of a horizontal padder from Wichelhaus GmbH. The speed of the rolls was set to 11 .6 m/min and the pressure between the rolls to 0.1 MPa. The material used in this study was airlaid nonwoven (fluff pulp fibers) and wetlaid nonwoven (mixed cellulosic fibers). After the impregnation, the material was put on a conveyer belt with the speed of 5 m/min which passed through a 3 m long oven heated to 160 °C. The material was acclimatized overnight in 23 °C and 50 %. Tensile testing was then performed on cut-out samples of 50 mm by 250 mm using a Testometric M250-2.5AT tensile testing machine. As a comparison, tensile testing was performed also on wetlaid and airlaid nonwoven material without applied binder. Ten specimen per trial were measured and the results from the tensile test can be found in Table 4. All values are mean values.
Table 4. Dry tensile test of wetlaid and airlaid nonwoven material
[0083] It can be seen in Table 4 that both flexibility (elongation) and strength (tensile index) increase substantially, both in the wetlaid and in the airlaid nonwoven material. For the airlaid nonwoven material, it is noted that the elongation after application of the binder composition was 5.4%, hence the material meets the high requirements on flexibility needed in many applications where airlaid nonwovens are used.
[0084] Example 3: Foamability of Binder A with two different foaming agents.
[0085] The foamability of Binder A with two different foaming agents was evaluated. A nonionic foaming agent (Glucopone 215 UP) and a zwitterionic (amphoteric) foaming agent (Ammonyx LO) were tested.
[0086] Binder A was diluted from a dry weight of 26 wt% (measured with a moisture analyser from VWR) to a dry weight of 14 wt%. 100 g of the dilution of Binder A and 1 g of the respective foaming agent were added to a 250 ml beaker. The mixture was mixed with a propeller at 1500 rpm for 5 min. The height of the
foam phase was measured directly after mixing and 5 minutes after finishing of the mixing. The results are shown in Table 5 below.
Table 5. Foam test of Binder A with different foaming agents
[0087] The experiment showed that Binder A was foamable with both the tested foaming agents and that the foams keep stable for at least 5 minutes, which allows for a smooth application of the binder with foam impregnation.
[0088] Example 4: Foam impregnation of Binder A on carded nonwoven material
[0089] Binder A was diluted from a dry weight of 26 wt% (measured with a moisture analyser from VWR) a dry weight of 10%. To 200 g of the dilution, 1 .67 g Glucopon 215 UP (foaming agent, nonionic surfactant) was added, and the mixture was stirred vigorously at 2000 rpm with a disperser assembled on an overhead stirrer from IKA Werke for 60 s. A dense and stable foam was observed. The foam was added between two compressed rolls of a horizontal padder from Wichelhaus GmbH. The speed of the rolls was set to 11.6 m/min and the pressure between the rolls to 0.1 MPa. A carded viscose nonwoven was passed through the
rolls. The nonwoven material was then dried in an oven from Termaks set at 170 °C for 3 min. The material was acclimatized overnight in 23 °C and 50 %RH. Tensile testing was then performed on cut-out samples of 50 mm by 250 mm using a Testometric M250-2.5AT tensile testing machine. As a comparison, tensile testing was performed also on carded nonwoven material without applied binder. Eight specimen per trial was measured and the results from the tensile test can be found in Table 6. All values are mean values.
Table 6. Dry tensile test of carded nonwoven material
[0090] The carded viscose nonwoven is in itself very elastic due to the long staple fibres that are building up the material. By applying the binder composition, a stiffer, yet stronger, material can be achieved, which is clearly illustrated by the increase in tensile stiffness index in the carded nonwoven material treated with the foamed binder composition.
Claims
1 . An aqueous biobased binder composition for a nonwoven material, said binder composition comprising an acid, a plasticizer and a cationic polyelectrolyte comprising chitosan, and wherein;
- the chitosan has a degree of deacetylation of 66 - 100%, and wherein the binder composition comprises 0.005 - 20 wt% of chitosan;
- the acid in the aqueous binder composition is a Bronsted acid and/or a Lewis acid, wherein the Bronsted acid is selected from any organic and/or inorganic acids, wherein the Lewis acid is selected from any cationic mono- or multivalent atom, and wherein the aqueous binder composition comprises preferably 0.01 - 30 wt% of acid;
- the aqueous binder composition comprises at least 0.5 wt% and less than 15 wt% of plasticizer, said plasticizer being a linear polyol selected from one or more of mannitol, maltitol, xylitol, and sorbitol, and/or a saccharide being a non- macrocyclic saccharide selected from one or more of glucose, mannose, fructose, sucrose, sucralose, sucrose esters, hydrolysed starch or dextrin;
- the pH of the binder composition is less than 7, and wherein the cationic polyelectrolyte is not in complex with an anionic polyelectrolyte.
2. The aqueous binder composition according to claim 1 , wherein the composition is substantially free from anionic polyelectrolyte.
3. The aqueous binder composition according to any one of the previous claims, wherein the composition comprises 0.01 - 11 wt%, such as 0.01 - 5 wt% or 0.01 - 2 wt% of acid.
4. The aqueous binder composition according to any one of the previous claims, wherein the composition comprises at least 1 wt%, such as at least 2 wt%, and less than 15 wt% of plasticizer.
5. The aqueous binder composition according to any one of the previous claims, wherein the composition comprises 0.005 - 10 wt% of chitosan, preferably 0.005 - 5 wt% of chitosan, or even more preferably 0.5 - 2.5 wt% of chitosan.
6. The aqueous binder composition according to any one of the previous claims, wherein the acid is selected from one or more of acetic acid, acetylsalicylic acid, adipic acid, benzenesulfonic acid, camphorsulfonic acid, citric acid, dihydroxy fumaric acid, formic acid, glycolic acid, glyoxylic acid, hydrochloric acid, lactic acid, malic acid, malonic acid, maleic acid, mandelic acid, oxalic acid, paratoluenesulfonic acid, phtalic acid, pyruvic acid, salicylic acid, sulfuric acid, tartaric acid and succinic acid, preferably lactic acid.
7. The aqueous binder composition according to any one of the previous claims, wherein the composition further comprises at least one additive selected from one or more of a defoamer, a foaming agent, a wetting agent, a coalescent agent, a catalyst, a surfactant, an emulsifier, a preservative, a cross-linker, a rheology modifier, a filler, a nonionic polymer, a dye and a pigment and wherein the concentration of the additive is 0-50% by weight, more preferably 0-30% by weight.
8. The aqueous binder composition according to any one of the previous claims, wherein the composition further comprises at least one foaming agent selected from one or more of an anionic surfactant, a cationic surfactant, a nonionic surfactant and an amphoteric surfactant.
9. The aqueous binder composition according to any one of the previous claims, wherein the composition comprises 0.5 - 2.5 wt% of chitosan, at least 2 wt% and less than 15 wt% of plasticizer, 0.05 - 3 wt% of acid and optionally 0.05 - 10 wt% of at least one or more of an additive selected from a defoamer, a foaming agent, a wetting agent, a coalescent agent, a catalyst, a surfactant, an emulsifier, a preservative, a cross-linker, a rheology modifier, a filler, a nonionic polymer, a dye and a pigment.
A method of treating a nonwoven material with a biobased binder composition, wherein the method comprises the steps of: a) providing a binder composition comprising an acid, a plasticizer and a cationic polyelectrolyte comprising chitosan, wherein the chitosan has a degree of deacetylation of 66 - 100%, the acid in the binder composition is a Bronsted acid and/or a Lewis acid, wherein the Bronsted acid is selected from any organic and/or inorganic acids, wherein the Lewis acid is selected from any cationic mono- or multivalent atom and wherein the cationic polyelectrolyte is not in a complex with an anionic polyelectrolyte; b) optionally, diluting the binder composition provided in step a); c) applying the composition of step a) or step b) to a nonwoven material by applying the binder composition on a formed nonwoven web, wherein the applied composition is a composition comprising 0.005 - 20 wt% of chitosan, at least 0.5 wt% and less than 15 wt% of plasticizer, wherein said plasticizer being a linear polyol selected from one or more of glycerol, mannitol, maltitol, xylitol, and sorbitol and/or a saccharide being a non-macrocyclic saccharide selected from one or more of glucose, mannose, fructose, sucrose, sucralose, sucrose esters, hydrolysed starch or dextrin, 0.01 - 30 wt% of acid and optionally 0.05 - 10 wt% of at least one or more of an additive selected from a defoamer, a foaming agent, a wetting agent, a coalescent agent, a catalyst, a surfactant, an emulsifier, a preservative, a cross-linker, a rheology modifier, a filler, a nonionic polymer, a dye and a pigment.; d) optionally curing the treated nonwoven material, preferably wherein the curing is performed at 20 to 200 degrees C. The method according to claim 10, wherein the nonwoven material is selected from one or more of an airlaid nonwoven material, a wetlaid nonwoven material and a carded nonwoven material. The method according to any one of the claims 10 - 11 , wherein the nonwoven material is substantially based on natural fibres such as wood fibers (e.g. pulp), fluff pulp, hemp fibres or man-made biobased fibres such as viscose, lyocell and PLA.
The method according to any one of the claims 10 - 12 wherein the binder composition is applied to the nonwoven material by spraying the binder composition on the nonwoven material, by coating the binder composition on the nonwoven material, by impregnating the binder composition on the nonwoven material or by foam-impregnating the binder composition on the nonwoven material. The method according to any one of the claims 10 - 13, wherein the method results in higher elongation of the treated nonwoven material, preferably the method results in an elongation of at least 4 %, preferably at least 5% of the nonwoven material, said elongation being elongation at break measured according to standard Edana 20.2-89. A nonwoven material treated according to the method as defined in any one of claims 10 - 14. The nonwoven material according to claim 15, wherein the material exhibits an elongation of at least 4%, preferably at least 5%, said elongation being elongation at break measured according to standard Edana 20.2-89. Use of an aqueous binder composition according to any one of claims 1 - 9 for treating a nonwoven material.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SE2251277-6 | 2022-11-03 | ||
SE2251277A SE2251277A1 (en) | 2022-11-03 | 2022-11-03 | Biobased binder compositions for nonwoven materials |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2024096808A1 true WO2024096808A1 (en) | 2024-05-10 |
Family
ID=88779936
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/SE2023/051119 WO2024096808A1 (en) | 2022-11-03 | 2023-11-03 | Biobased binder compositions for nonwoven materials |
Country Status (2)
Country | Link |
---|---|
SE (1) | SE2251277A1 (en) |
WO (1) | WO2024096808A1 (en) |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2012015863A1 (en) | 2010-07-30 | 2012-02-02 | Wacker Chemical Corporation | Ultra low formaldehyde binders for nonwoven substrates |
WO2018038671A1 (en) | 2016-08-24 | 2018-03-01 | Organoclick Ab | Bio-based pec compositions as binders for fiber based materials, textiles, woven and nonwoven materials |
WO2020068151A1 (en) | 2018-09-26 | 2020-04-02 | Georgia-Pacific Nonwovens LLC | Latex-free and formaldehyde-free nonwoven fabrics |
WO2022139670A1 (en) * | 2020-12-21 | 2022-06-30 | Organoclick Ab | Binder compositions |
WO2022235189A1 (en) * | 2021-05-04 | 2022-11-10 | Organoclick Ab | Biobased binder compositions for airlaid nonwoven materials |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB977708A (en) * | 1960-01-04 | 1964-12-09 | Walter Palfrey | Non-woven fabrics |
JP4765255B2 (en) * | 2004-03-08 | 2011-09-07 | 富士ゼロックス株式会社 | Inkjet liquid composition and inkjet recording method |
PL214227B1 (en) * | 2006-02-24 | 2013-07-31 | Inst Wlokien Chem | Method for the obtainment of unwoven fabric with high dispersing capacity in water |
-
2022
- 2022-11-03 SE SE2251277A patent/SE2251277A1/en unknown
-
2023
- 2023-11-03 WO PCT/SE2023/051119 patent/WO2024096808A1/en unknown
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2012015863A1 (en) | 2010-07-30 | 2012-02-02 | Wacker Chemical Corporation | Ultra low formaldehyde binders for nonwoven substrates |
WO2018038671A1 (en) | 2016-08-24 | 2018-03-01 | Organoclick Ab | Bio-based pec compositions as binders for fiber based materials, textiles, woven and nonwoven materials |
WO2020068151A1 (en) | 2018-09-26 | 2020-04-02 | Georgia-Pacific Nonwovens LLC | Latex-free and formaldehyde-free nonwoven fabrics |
WO2022139670A1 (en) * | 2020-12-21 | 2022-06-30 | Organoclick Ab | Binder compositions |
WO2022235189A1 (en) * | 2021-05-04 | 2022-11-10 | Organoclick Ab | Biobased binder compositions for airlaid nonwoven materials |
Also Published As
Publication number | Publication date |
---|---|
SE2251277A1 (en) | 2024-05-04 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US9926655B2 (en) | Entangled substrate of short individualized bast fibers | |
KR100585930B1 (en) | Condrapable hydrophobic nonwoven web and method of making same | |
EP2776619B1 (en) | Nonwoven comprising a cellulosic fibre with hydrophobic properties and high softness | |
EP2781652B2 (en) | Wet-laid nonwoven comprising nanofibrillar cellulose and a method of manufacturing such | |
EP3856123B1 (en) | Latex-free and formaldehyde-free nonwoven fabrics | |
EP3504263A1 (en) | Bio-based pec compositions as binders for fiber based materials, textiles, woven and nonwoven materials | |
US20210054548A1 (en) | Modified Cellulose-Based Natural Binder for Nonwoven Fabrics | |
CN114929958B (en) | Flexible soft tissue comprising individualized bast fibers | |
WO2021228868A1 (en) | Non-woven fabric containing a disinfecting agent and method for producing the same | |
EP4308660A1 (en) | Biobased binder compositions for airlaid nonwoven materials | |
WO2024096808A1 (en) | Biobased binder compositions for nonwoven materials | |
WO2022139670A1 (en) | Binder compositions | |
US20240218577A1 (en) | Biobased binder compositions for airlaid nonwoven materials | |
TW202111174A (en) | Modified cellulosic fibers | |
US20230212799A1 (en) | Method for consolidating a fibrous material with a bio-based binder polymer, a consolidated fibrous material and an aqueous binder solution | |
JP2024503528A (en) | Hydrophobic cellulose fiber |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 23805216 Country of ref document: EP Kind code of ref document: A1 |