Article comprising a flexible material of a non-woven, the flexible material treated with polycarboxy emulsion copolymer binder compositions

摘要

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.

主权项

1. An article comprising:
a flexible material of a non-woven, the flexible material treated with a binder composition of (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, the polyol crosslinker comprising 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 0.25:1 to 2.0:1, wherein, the flexible material is selected from (i) a facing sheet chosen from a fibrous sheet, roving, mat or a pultruded fibrous material in a gypsum wallboard or panel comprising a gypsum core layer sandwiched between facing sheets and (ii) a sheet, roving or mat which is a carpet backing.