Abstract: This invention is directed to alkylphenol ethoxylate (APE)-free polymer binders formed by aqueous free radical emulsion polymerization and having specific peel and cure properties. The APE-free polymeric binders have a peel value, when adhered to a heated metal surface, of 35% to 200% of the peel value shown by a standard APE-based polymer binder control and exhibit a cure profile such that at least 55% cure is achieved within 30 seconds at a temperature required for cure, and a wet tensile strength at 30-seconds of cure of at least 1000 g/5 cm. Wet tensile strength is used as a measure of cure. Binders having the peel and cure properties described herein can be considered for use in crepe processes, especially DRC processes.

Abstract: This invention is directed to an improvement in a crosslinkable vinyl acetate/vinyl versatate based polymeric binder for use in nonwoven applications. The improvement in the binder for nonwoven and, particularly premoistened wipes, resides in a polymer comprised of vinyl acetate and vinyl versatate produced by either of the methods: batch polymerization where polymerized units of an in situ or internal crosslinking (polyolefinically unsaturated) monomer are incorporated into the polymer; or, delayed addition of vinyl versatate where the vinyl versatate is polymerized into the polymer by delayed addition such that vinyl versatate rich polymer segments are formed; and, preferably, polymerized units of a polyolefinically unsaturated monomer are incorporated into the polymer.

Abstract: This invention is directed to formation of a creped nonwoven web. The creped web is formed in a creping process using a polymer emulsion binder formed in an alkylphenol ethoxylate-free surfactant system. The surfactant system comprises a combination of a specific active anionic surfactant (sodium laureth sulfate containing 1 to 12 moles of ethylene oxide) and a specific active nonionic surfactant (a secondary alcohol ethoxylate containing 7 to 30 moles of ethylene oxide or an ethoxylated branched primary alcohol containing 3 to 30 moles of ethylene oxide.

Abstract: This invention is directed to APE-free polymer binders formed by emulsion polymerization and having specific peel and cure properties. The APE-free polymeric binders have a peel value, when adhered to a heated metal surface, of 35% to 200% of the peel value shown by a standard APE-based polymer binder control (i.e., AIRFLEX® 105 vinyl acetate-ethylene polymer emulsion) and exhibit a cure profile such that at least 55% cure is achieved within 30 seconds at a temperature required for cure. Wet tensile strength is used as a measure of cure. The peel value is determined by a modified release and adhesion test. Binders having the peel and cure properties described herein can be considered for use in crepe processes, especially DRC processes.

Abstract: The free formaldehyde content of the emulsion polymer, the amount of emitted formaldehyde and, even more particularly, of the finished nonwoven or textile may be substantially reduced by the use of a particular initiator system comprising a hydrophobic hydroperoxide and ascorbic acid. Moreover, this reduction in formaldehyde levels is accompanied by an unexpected improvement in the tensile properties of the emulsion binders.

Abstract: Formaldehyde-free heat resistant binders for flexible nonwoven products may be prepared using an emulsion polymer comprising 100 parts by weight of C.sub.1 -C.sub.4 alkyl acrylate or methacrylate or styrene/acrylate ester monomers, 0.5 to 5 parts of a hydroxyalkyl acrylate or methacrylate, 3 to 6 parts of methyl acrylamido glycolate methyl ether and 0.1 to 5 parts of a multifunctional comonomer. The binders are useful in the formation of heat resistant flexible products for use in roofing, flooring and filtering materials.

Abstract: Heat resistant binders for flexible nonwoven products may be prepared using an emulsion polymer comprising 100 parts by weight of C.sub.1 -C.sub.4 alkyl acrylate or methacrylate ester monomers, 0.5 to 5 parts of a hydroxyalkyl acrylate or methacrylate, 3 to 6 parts of a water soluble N-methylol containing comonomer and 0.1 to 5 parts of a multifunctional comonomer. The binders are useful in the formation of heat resistant flexible products for use in roofing, flooring and filtering materials.

Abstract: Heat resistance binders for flexible polyester webs may be prepared using an emulsion polymer,the polymer being prepared by a two-stage polymerization procedure wherein a first stage is prepared based on a relatively low Tg ethylene vinyl acetate polymer and a second stage higher Tg polymer thereby combining the advantageous flexibility and film forming properties of the ethylene vinyl acetate copolymer with the stiffness and heat resistance of the higher Tg copolymer.

Abstract: Heat resistant binders for flexible nonwoven mats may be prepared using an emulsion polymer comprising 100 parts by weight of acrylate or styrene/acrylate monomers, 3 to 6 parts of a blocked, N-methylol containing comonomer, 0 to 3 parts of a water soluble non-blocked N-methylol containing comonomer and 0 to 5 parts of a multifunctional comonomer. The use of the blocked N-methylol containing comonomer permits the incorporation into the latex binders of higher levels of N-methylol functionality with consequent increase in heat resistance. As such, the binders are useful in the formation of heat resistant flexible mats for use in roofing, flooring and filtering materials.

Abstract: Heat resistant binders for flexible nonwoven mats may be prepared using an emulsion polymer comprising 100 parts by weight of acrylate or styrene/acrylate monomers, 3 to 6 parts of a blocked, N-methylol containing comonomer, 0 to 3 parts of a water soluble non-blocked N-methylol containing comonomer and 0 to 5 parts of a multifunctional comonomer. The use of the blocked N-methylol containing comonomer permits the incorporation into the latex binders of higher levels of N-methylol functionality with consequent increase in heat resistance. As such, the binders are useful in the formation of heat resistant flexible mats for use in roofing, flooring and filtering materials.