Lipid Ester Master Batch Composition for Hydrophobic Non-Woven Fabrics

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Solution Overview

Problem

Current non-woven fabrics require fluorinated or silicone-based coatings to effectively repel low surface tension fluids, which can cause skin irritation and are difficult and labor-intensive to apply, necessitating a more efficient and skin-friendly hydrophobic solution.

Innovation Solution

A master batch composition comprising a polymer and a lipid ester, such as triglyceride ester, is used to increase the hydrophobicity of fabrics and fibers, providing a barrier against low surface tension fluids without the use of fluorine-based chemicals, by compounding the ester with a carrier polymer to form a soft or compacted pellet that can be easily blended with a matrix polymer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fluorinated coatings are applied to non-woven fabrics to achieve fluid repellency, then low surface tension fluid repellency is improved, but skin irritation occurs during prolonged exposure

Engineering Contradiction:

Improvefluid repellencyVSAvoidskin irritation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and removes fluorinated compounds from the coating composition, replacing them with alternative hydrophobic agents that do not cause skin irritation. This is achieved by formulating coatings without fluorinated substances while maintaining fluid repellency through other means.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs alternative coating materials that are safer for skin contact, even if they require more frequent reapplication. The focus shifts to using disposable or easily replaceable coating layers that prioritize user safety over long-term durability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If silicone components are applied to non-woven fabrics to achieve fluid repellency, then low surface tension fluid repellency is improved, but manufacturing complexity and labor intensity increase significantly

Engineering Contradiction:

Improvefluid repellencyVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines hydrophobic agents with the fiber material itself during the fiber formation process, rather than applying separate silicone coatings. This integration simplifies manufacturing by eliminating additional coating steps and reduces labor intensity while maintaining fluid repellency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hydrophobic properties are built into the fiber structure during the initial fiber formation process, before the non-woven fabric is assembled. This preliminary action eliminates the need for subsequent coating operations, simplifying the overall manufacturing process.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If conventional coatings are applied to non-woven fabrics to achieve fluid repellency, then low surface tension fluid repellency is improved, but manufacturing cost and labor intensity increase

Engineering Contradiction:

Improvefluid repellencyVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The hydrophobic properties are incorporated into the fiber material during the extrusion and formation process, before the non-woven fabric is assembled. This preliminary action eliminates the need for subsequent coating operations, simplifying the overall manufacturing process and improving productivity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The functional properties are merged with the base fiber material, creating a single integrated product that requires only one manufacturing process rather than multiple sequential steps, thereby improving manufacturing efficiency and reducing costs.

Inventive Principle:

Principle #5Merging (Combining)

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 resulting non-woven fabrics exhibit improved hydrophobicity with contact angles ranging from 100° to 125°, effectively repelling low surface tension fluids while being easy to manufacture and safe for prolonged skin contact, with the lipid ester migrating minimally and maintaining repellency through routine use.

Implementation Method 1

a master batch composition for use in preparing a non-woven fabric in order to increase the hydrophobicity of the non-woven fabric

Methodology Applied

Scientific EffectHydrophobicity: Hydrophobe

Implementation Method 2

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

Methodology Applied

Scientific EffectContact angle: Wetting

Data Source

PatentUS10189959B2Hydrophobic additive for use with fabric, fiber, and film

Publication Date: 2019.01.29 TECHMER PM LLC

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 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.