Lipid Ester Masterbatch for Hydrophobic Non-Woven Fabric Barriers
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Solution Overview
Problem
Current non-woven fabrics used as barriers for low surface tension fluids, such as contaminated bodily fluids, often require fluorinated or silicone-based coatings that can cause skin irritation and are difficult and costly to manufacture, especially when trying to achieve effective fluid repellency.
Innovation Solution
A master batch composition is used to increase the hydrophobicity of non-woven fabrics, films, and fibers, comprising a polymer and a lipid ester, such as a triglyceride ester, which forms a contact angle of 100° to 125°, providing effective fluid repellency without the use of fluorine-based or other halogen-based chemicals, and is easier and less expensive to manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluorinated coatings are applied to non-woven fabrics to achieve fluid repellency, then effective barrier properties against low surface tension fluids are obtained, but skin irritation occurs during prolonged exposure
Solution Approach 1:
The patent removes fluorinated compounds and other halogen-based chemicals from the non-woven fabric composition entirely, replacing them with hydrocarbon-based polymers and waxes that provide equivalent fluid repellency without causing skin irritation. This extraction of harmful substances while maintaining protective function directly resolves the contradiction between effective barrier properties and skin safety.
2Reliability
If silicone components are applied to non-woven fabrics to achieve fluid repellency, then effective barrier properties are obtained, but the manufacturing process becomes extremely difficult and labor-intensive
Solution Approach 1:
The patent combines hydrophobic polymers and waxes into a single integrated composition that is incorporated directly into the non-woven fabric manufacturing process. This unified approach eliminates the need for separate silicone coating operations, reducing manufacturing steps and labor requirements while maintaining effective fluid repellency.
3Reliability
If fluorinated coatings are used to achieve effective fluid repellency, then low surface tension fluid barrier properties are improved, but manufacturing costs increase
Solution Approach 1:
The patent employs conventional hydrocarbon-based polymers and waxes that are significantly less expensive than fluorinated compounds. These materials provide sufficient fluid repellency for the intended application lifecycle at a fraction of the cost of fluorinated alternatives, making the non-woven fabric economically viable while maintaining protective function.
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 solution effectively repels low surface tension fluids while avoiding skin irritation and simplifying the manufacturing process, offering improved barrier properties for non-woven fabrics without the use of harmful halogen-based chemicals, with the lipid ester migrates minimally and can be easily removed, maintaining repellency.
Implementation Method 1
increase the hydrophobicity of the non-woven fabric... has a contact angle ranging from 100° to 125°... effectively repels low surface tension fluids
Implementation Method 2
compounding a polymer with a lipid ester... The lipid ester comprises from 10 wt. % to 40 wt. % of the master batch... has a contact angle ranging from 100° to 125°
Data Source
AI summary
The present invention relates to a hydrophobic additive for use with fabric, fiber, and film. One aspect of the present invention comprises a master batch composition for use in preparing a non-woven fabric in order to increase the hydrophobicity of the non-woven fabric. In one embodiment, the master batch composition includes a polymer and a lipid ester. The lipid ester comprises from 10 wt. % to 40 wt. % of the master batch. The fabric, when including the master batch composition, has a contact angle ranging from 100° to 125° when measured according to test method ASTM D2578.