Formaldehyde-free binder for nonwoven fabrics

Claim 1

A substantially formaldehyde-free binder composition formed from the polymerization of an alkyl acrylamido glycolate alkyl ether or an acrylamido glycoamide alkyl ether having the following respective general structures: (a) wherein R is hydrogen or methyl, R′ is selected from alkyls of 1-6 carbon atoms and cycloalkyls of 5-6 carbon atoms, R² is selected from alkyls of 1-6 carbon atoms and cycloalkyls of 5-6 carbon atoms, each of which is optionally substituted with oxygen or nitrogen heteroatoms, and R³ and R⁴ are selected from hydrogen, alkyls or cycloaliphatic alkyls of 1 to 20 carbons optionally modified with nitrogen or oxygen moieties; and (b) a comonomer selected from the group consisting of comonomers such as acrylic and methacrylic acid and their methyl, ethyl, propyl, butyl and 2-ethyl hexyl esters; styrene, methylstyrene, styrene-butadiene and ethylstyrene; vinyl esters such as vinyl acetate, vinyl propionate, vinyl butyrate; vinyl versatate, itaconic acid and its mono or diethyl propyl and butyl esters, fumaric acid and its mono or di-propyl, butyl and ethyl esters; maleic acid and its mono or di-propyl, butyl and ethyl esters; acryl- and methacrylamides and their alkylates, olefins such as ethylene, propylene, butadiene and the like; and wherein said composition also contains a reactive function selected from the group consisting of hydroxy, carboxy, amido, and combinations thereof.

Claim 5

A method for forming a substantially formaldehyde free nonwoven fabric comprising contacting a web or mass of fibers with a binder composition comprising the polymerization of an alkyl acrylamido glycolate alkyl ether or an acrylamido glycoamide alkyl ether having the following respective general structures: (a) wherein R is hydrogen or methyl, R′ is selected from alkyls of 1-6 carbon atoms and cycloalkyls of 5-6 carbon atoms, R² is selected from alkyls of 1-6 carbon atoms and cycloalkyls of 5-6 carbon atoms, each of which is optionally substituted with oxygen or nitrogen heteroatoms, and R³ and R⁴ are selected from hydrogen, alkyls or cycloaliphatic alkyls of 1 to 20 carbons optionally modified with nitrogen or oxygen moieties; and (b) a comonomer selected from the group consisting of comonomers such as acrylic and methacrylic acid and their methyl, ethyl, propyl, butyl and 2-ethyl hexyl esters; styrene, methylstyrene, styrene-butadiene and ethylstyrene; vinyl esters such as vinyl acetate, vinyl propionate, vinyl butyrate; vinyl versatate, itaconic acid and its mono or diethyl propyl and butyl esters, fumaric acid and its mono or di-propyl, butyl and ethyl esters; maleic acid and its mono or di-propyl, butyl and ethyl esters; acryl- and methacrylamides and their alkylates, olefins such as ethylene, propylene, butadiene and the like; and wherein said composition is imparted with a reactive function selected from the group consisting of hydroxy, carboxy, amido, and combinations thereof.

Claim 6

A method for forming a substantially formaldehyde free nonwoven fabric comprising contacting a web or mass of fibers with a binder composition comprising the polymerization of an alkyl acrylamido glycolate alkyl ether or an acrylamido glycoamide alkyl ether having the following respective general structures: (a) wherein R is hydrogen or methyl, R′ is selected from alkyls of 1-6 carbon atoms and cycloalkyls of 5-6 carbon atoms, R² is selected from alkyls of 1-6 carbon atoms and cycloalkyls of 5-6 carbon atoms, each of which is optionally substituted with oxygen or nitrogen heteroatoms, and R³ and R⁴ are selected from hydrogen, alkyls or cycloaliphatic alkyls of 1 to 20 carbons optionally modified with nitrogen or oxygen moieties; and (b) a comonomer selected from the group consisting of comonomers such as acrylic and methacrylic acid and their methyl, ethyl, propyl, butyl and 2-ethyl hexyl esters; styrene, methylstyrene, styrene-butadiene and ethylstyrene; vinyl esters such as vinyl acetate, vinyl propionate, vinyl butyrate; vinyl versatate, itaconic acid and its mono or diethyl propyl and butyl esters, fumaric acid and its mono or di-propyl, butyl and ethyl esters; maleic acid and its mono or di-propyl, butyl and ethyl esters; acryl- and methacrylamides and their alkylates, olefins such as ethylene, propylene, butadiene and the like; and wherein said composition is imparted with a reactive function selected from the group consisting of hydroxy, carboxy, amido, and combinations thereof.