Composite Nonwoven Mat With Polymer Barrier Against Liquid Bleed-Through
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Solution Overview
Problem
Conventional nonwoven mats have a porous structure that allows liquid materials to bleed through, which is undesirable in certain applications.
Innovation Solution
A composite nonwoven mat is developed, comprising a nonwoven base layer with a polymer layer adhered to its surface, where the polymer layer extends partially into the base layer, creating an impervious barrier to prevent liquid penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a porous nonwoven mat structure is used, then wetting and bonding are enabled, but liquid bleed-through occurs
Solution Approach 1:
The nonwoven mat is segmented into multiple functional layers: a porous base layer for wetting and bonding, and an impervious polymer layer for bleed prevention. Each layer performs a specific function, resolving the contradiction between porosity and bleed resistance.
Solution Approach 2:
The invention combines different materials with complementary properties: a porous nonwoven base material (providing wetting and bonding) and an impervious polymer material (providing bleed prevention). This composite structure resolves the technical contradiction by integrating materials that individually address different requirements.
2Object-generated harmful factors
If an impervious polymer layer is added to prevent bleed-through, then liquid penetration is blocked, but the structure becomes more complex
Solution Approach 1:
A thin polymer film or coating is applied to the nonwoven mat surface to create an impervious barrier. This thin-film approach prevents liquid bleed-through while minimizing the increase in structural complexity and maintaining flexibility.
Solution Approach 2:
The invention creates a composite material system where a simple polymer layer is combined with the nonwoven base layer. This composite approach achieves bleed prevention without requiring complex multi-component systems or intricate structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite nonwoven mat effectively prevents liquid bleed-through, maintaining a sealed surface while retaining porosity for wetting and bonding, suitable for applications like flooring and roofing materials.
Implementation Method 1
a polymer layer adhered to the first surface of the nonwoven base layer
Implementation Method 2
The polymer layer extends partially into the nonwoven base layer... effectively prevents liquid bleed-through, maintaining a sealed surface
Data Source
AI summary
A composite nonwoven mat and a method of making a composite nonwoven mat are provided. The composite nonwoven mat includes a nonwoven base layer having a first surface and a second surface, and a polymer layer formed on and adhered to the first surface of the nonwoven base layer. The polymer layer extends partially into the nonwoven base layer. The composite nonwoven mat has an average Gurley porosity of at least 2,000 seconds.