Polycarboxy emulsion copolymer binder compositions

Abstract

The present invention provides flexible binder compositions comprising one or more polycarboxy emulsion copolymer has a measured Tg of 40° C. or less, such as from −45° C. to 25° C., and a polyol crosslinker. In one embodiment, the binder compositions comprising the polycarboxy emulsion copolymer can be used in making pultruded composites, such as sheets, for example, flexible gypsum board facing sheets, and flexible non-woven articles such as, for example, carpet backing.

1 . A flexible binder composition comprising:
 (a) one or more polycarboxy emulsion copolymer polymerized from 10 wt. % to 25 wt. % of a carboxy acid monomer, based on the total weight of monomers in the copolymer, wherein the polycarboxy emulsion copolymer has a measured Tg of from −45° C. to 25° C., and a total solids of no less than 40 wt. %; and,   (b) at least one polyol crosslinker having a molecular weight of less than 700, wherein said polyol crosslinker comprises a primary hydroxy group and at least one additional hydroxy group, wherein the ratio of primary hydroxy group equivalents to carboxy group equivalents is from 0.25 to 2.0.   
   
   
       2 . The binder composition as claimed in  claim 1 , wherein the polycarboxy emulsion copolymer has a measured Tg of from 0° C. to 25° C. 
   
   
       3 . The binder composition as claimed in  claim 2 , wherein the polycarboxy emulsion copolymer comprises a pre-crosslinked copolymer. 
   
   
       4 . The binder composition as claimed in  claim 1  which consists essentially of the one or more polycarboxy emulsion copolymer and the at least one polyol. 
   
   
       5 . A process of making a flexible non-woven fiber article comprising pultruding two or more non-woven fibers or a fiber roving with the binder compositions of  claim 1 , and drying. 
   
   
       6 . A process as claimed in  claim 4 , wherein the binder compositions comprise one or more flexible polycarboxy emulsion copolymer has a measured Tg of from 0° C. to 25° C. 
   
   
       7 . The flexible binder composition as claimed in  claim 1 , wherein the polycarboxy emulsion copolymer has a measured Tg of from −45° C. to −5° C. 
   
   
       8 . A flexible product comprising a non-woven fiber mat of fibers and the binder composition as claimed in  claim 7 .