Binders & Additives II

This presentation overviews the development of a new, APE FREE Monoester Sulfosuccinate Surfactant designed to assist in the synthesis of emulsion polymer products for the nonwovens industries. This new product has been developed as a result of market expressed interest for alternative emulsifiers systems to current APE (Alkyl phenol ethoxylate) containing products that are continuing to experience increased governmental regulations and public scrutiny. This paper will compare and contrast the performance of this new product with those of an APE based monoester sulfosuccinate. Specific information will be presented on the properties and characteristics of the new product nd sample recipes will be presented on the properties and characteristics of the new product and sample recipes will be presented demonstrating performance in acrylic and vinyl acrylic based nonwoven latex systems. Information will also be presented on the impact of the surfactant on latex properties and characteristics. The new product is recommended for usage as either a primary or co-emulsifier in latex systems.

Over the last few years, groundbreaking scientific discoveries have been made in molecular biology, the basis of biotechnology. We want to use this new knowledge of enzyme fermentation and catalysis to develop new products, processes, and system solutions. 

Fermentation and enzyme manipulation are the technologies shown to be effective in the following areas: 

• Renewable raw materials can be increased through fermentative processes, which is an advantage during times of rising crude oil prices.   
• Previously identified as an area for major growth in the industry is the use of enzymes to improve the selectivity of chemical reactions.  This is specifically useful in the manufacture of intermediates and monomers.
• Metabolic engineering further uses fermentation to selectively modify the genetic material of the organisms so that they deliver products not synthesized in nature.

Harnessing biotechnology in these ways can open the door to opportunities to yield improvement as well as designing novel monomers for products, such as binders, adhesives, coatings, etc, which deliver new and improved performances that have not been possible via traditional methods.

With the continued strong growth in the consumption of nonwoven materials by both consumer and industrial applications, there exists an increasing focus on the detrimental consequences of disposing of this vast volume of material.  As a result, we are facing a surging trend in the development of sustainable and more eco-friendly products. 

Strength and durability remain primary functional requirements for most nonwoven applications, yet these attributes become negative traits once the article is disposed.  The ideal system would provide these fundamental properties for normal service, and then once discarded, undergo enough of a reversal in bonding to afford total dissolution of the nonwoven into its constituent parts.  In this form, the article would occupy less landfill space or be less conspicuous or detrimental in the environment. 

By using select components in the design of a novel polymer, we will show a step-change improvement in the performance of a hydrogen bonding system. These select components provide for a stronger, reversible, hydrogen bond in contrast to the standard, less reversible associations of current commercial technologies utilizing acid-containing acrylic, polyvinyl acetate, or polyvinyl alcohol binders. The balance of strength with rate of dispersibility can be tailored within a range to meet a specific performance application.

The DyStar Group at a glance
Here I give a short introduction to DyStar the international leader in textile dyes.

Evo Top® Ceramic Coatings
Basic information about the products and how we invented this composite materials.

What is ceramic?
The Definition of ceramic and the historical background of this ancient technology.

Basics of ceramic coating on nonwovens
Application and construction of coatings on nonwovens, basic technical information about application systems from knife coating to nip padding.

Examples: 
Boron nitride, Silicon carbide (SiC), Aluminium oxid (Al2O3) Zirkoniumdioxid (ZrO2), Titandioxid (TiO2), Magnesiumoxid (MgO), Tricalciumphosphat  Bariumtitanat (BaO + TiO2) Tantalcarbid (CTa), Wolframcarbid (WC), Bariumsulfat (Baryt), Zinkoxid (ZnO)
Here I show the different effects of the ceramic particles in the composite coating film.

Ecology

• Ceramic-Compounds are pure water based compounds,
• 100% solvent free
• They are free of:
• Formaldehyde,
• Halogens
• Heavy metals
• Oeko Tex standard 100 possible

Repellence of liquid metal, based on not burning nonwovens or flame protected viscose etc.
Cooperation of DyStar and DuPont, coatings can protect human health or technical goods, stability against liquid Iron, Zinc, Copper, Aluminum and Magnesium

Improvement of flame retardant abilities
Coatings absorb heat and infrared, high thermal stability, excellent heat resistance up to 1000°C

Evo Top® Ceramic-Coating for military use
Camouflage articles and covers
Armored cars, airplanes and helicopters

Ceramic coatings are highly effective in:

• Scratch resistance
• High temperature stability
• IR absorbance
• UV protection
• Cut proof coatings
• Bullet proof applications
  (Body armor and protection of vehicles)
• Flame retardant coatings