Aqueous binders for granular and/or fibrous substrates

Abstract

Binder for granular and/or fibrous substrates

1 . An aqueous binder composition comprising
 a) at least one polymer P constructed from
 ≧0.1 and ≦2.5 wt % of at least one acid-functional ethylenically unsaturated monomer (monomers A) 
 ≧0 and ≦4.0 wt % of at least one ethylenically unsaturated carboxylic acid nitrile or dinitrile (monomers B) 
 ≧0 and ≦2.0 wt % of at least one crosslinking monomer having two or more nonconjugated ethylenically unsaturated groups (monomers C) 
 ≧0 and ≦10 wt % of at least one α,β-monoethylenically unsaturated C 3  to C 6  mono- or dicarboxamide (monomers D) 
 ≧25 and ≦69.9 wt % of at least one ethylenically unsaturated monomer whose homopolymer has a glass transition temperature ≦30° C. and which differs from the monomers A to D (monomers E), and 
 ≧30 and ≦70 wt % of at least one ethylenically unsaturated monomer whose homopolymer has a glass transition temperature 50° C. and which differs from the monomers A to D (monomers F), 
 in polymerized form, wherein the amounts of monomers A to F sum to 100 wt %, and 
   b) at least one saccharide compound S, the amount of which is determined such that it is ≧10 and ≦400 parts by weight per 100 parts by weight of polymer P.   
     
     
         2 . The aqueous binder composition according to  claim 1  wherein the at least one monomer E is selected from the group comprising conjugated aliphatic C 4  to C 9  diene compounds, esters of vinyl alcohol and a C 1  to C 10  monocarboxylic acid, C 1  to C 10  alkyl acrylate, C 5  to C 10  alkyl methacrylate, C 5  to C 10  cycloalkyl acrylate, C 5  to C 10  cycloalkyl methacrylate, C 1  to C 10  dialkyl maleinate and/or C 1  to C 10  dialkyl fumarate and the at least one monomer F is selected from the group comprising vinylaromatic monomer and/or C 1  to C 4  alkyl methacrylate. 
     
     
         3 . The aqueous binder composition according to  claim 1  or  2  wherein the polymer P comprises ≧0.1 and ≦1.5 wt % of at least one monomer C in polymerized form. 
     
     
         4 . The aqueous binder composition according to any one of  claims 1  to  3  wherein the polymer P is used in the form of an aqueous polymer dispersion. 
     
     
         5 . The aqueous binder composition according to  claim 4  wherein the polymer particles of the aqueous polymer dispersion have a number average particle diameter ≧50 and ≦400 nm. 
     
     
         6 . The aqueous binder composition according to any one of  claims 1  to  5 , wherein the polymer P is constructed from
 ≧0.5 and ≦2.0 wt % of at least one monomer A 
 ≧0.1 and ≦1.5 wt % of at least one monomer C 
 ≧0 and ≦4.0 wt % of at least one monomer D 
 ≧30 and ≦60 wt % of at least one monomer E, and 
 ≧40 and ≦70 wt % of at least one monomer F. 
 
     
     
         7 . The aqueous binder composition according to any one of  claims 1  to  6  wherein the polymer P is constructed from
 ≧1.0 and ≦2.0 wt % of acrylic acid, methacrylic acid and/or itaconic acid 
 ≧0.3 and ≦1.2 wt % of 1,4-butylene glycol diacrylate, allyl methacrylate and/or divinylbenzene 
 ≧0 and ≦4.0 wt % of acrylamide, methacrylamide, N-methylolacrylamide and/or N-methylolmethacrylamide 
 ≧30 and ≦50 wt % of 2-ethylhexyl acrylate, n-butyl acrylate, 1,4-butadiene and/or ethyl acrylate, and 
 ≧40 and ≦60 wt % of methylmethacrylate, styrene and/or tert-butyl methacrylate. 
 
     
     
         8 . The aqueous binder composition according to any one of  claims 1  to  7  wherein type and amount of monomers A, B, D, E and F are chosen such that a polymer formed from them would have a glass transition temperature ≧5 and ≦35° C. 
     
     
         9 . The aqueous binder composition according to any one of  claims 1  to  8  wherein the at least one saccharide compound S comprises starch, cellulose, guaran, xanthan, alginate, pectin, chitosan, gum arabic and/or gellan. 
     
     
         10 . The aqueous binder composition according to any one of  claims 1  to  9  wherein a starch, a starch derivative and/or substitution products thereof is or are used as saccharide compound S. 
     
     
         11 . The aqueous binder composition according to any one of  claims 1  to  10  wherein the saccharide compound S has a weight average molecular weight ≧5000 and ≦25 000 g/mol. 
     
     
         12 . The aqueous binder composition according to any one of  claims 1  to  11  wherein ≧10 and ≦70 parts by weight of saccharide compound S are used per 100 parts by weight of polymer P. 
     
     
         13 . The aqueous binder composition according to any one of  claims 1  to  12  comprising ≦1 wt % of a polyol compound having a molecular weight ≦200 g/mol with two or more hydroxyl groups, based on the summed overall amounts of polymer P and saccharide compound S. 
     
     
         14 . The use of an aqueous binder composition according to any one of  claims 1  to  13  as binder for granular and/or fibrous substrates and also noncementitious coatings, sealants and adhesives. 
     
     
         15 . A process for producing a shaped article from granular and/or fibrous substrates wherein an aqueous binder composition according to any one of  claims 1  to  13  is applied to the granular and/or fibrous substrate, the granular and/or fibrous substrate thus treated is optionally shaped and then the granular and/or fibrous substrate thus obtained is subjected to a thermal treatment step at a temperature ≧110° C. 
     
     
         16 . The process for producing a shaped article according to  claim 15  wherein the amount of aqueous binder composition is chosen such that ≧1 and ≦100 g of binder (corresponding to the summed overall amounts of polymer P and polysaccharide compound S) are applied per 100 g of granular and/or fibrous substrate. 
     
     
         17 . A shaped article obtainable by a process according to either of  claims 15  and  16 . 
     
     
         18 . The use of a shaped article according to  claim 17  for producing bituminized roofing membranes. 
     
     
         19 . A bituminized roofing membrane obtained using a shaped article according to  claim 17 . 
     
     
         20 . An aqueous polymer dispersion whose polymer is constructed from
 ≧0.1 and ≦2.5 wt % of at least one monomer A   ≧0 and ≦4.0 wt % of at least one monomer B   ≧0 and ≦2.0 wt % of at least one monomer C   ≧0 and ≦10 wt % of at least one monomer D   ≧25 and ≦69.9 wt % of at least one monomer E, and   ≧30 and ≦70 wt % of at least one monomer F,   wherein the amounts of monomers A to F sum to 100 wt %, in polymerized form.