Nonwoven Fabrics Using Amide Additives for Liquid Barrier
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Solution Overview
Problem
There is a need for cost-effective nonwoven fabrics with enhanced liquid barrier properties suitable for various applications, as existing methods like incorporating fluorochemicals are expensive and not economically viable for all applications.
Innovation Solution
Incorporating a liquid-barrier-enhancing additive (LBEA) comprising an amide into the polymer melt to form nonwoven fabrics, which can be used in the production of layers for nonwoven fabrics, providing improved liquid barrier properties without increasing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluorochemicals are incorporated to improve barrier properties, then liquid barrier properties are enhanced, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive fluorochemical additives with cheaper alternative additives that provide comparable liquid barrier properties. The specification describes using alternatives such as carboxylic acid salts, sulfonate salts, or other inexpensive surfactants that can be incorporated into the nonwoven fabric at lower cost while maintaining adequate barrier performance for the application
Solution Approach 2:
The patent modifies the chemical composition parameters by substituting fluorochemical compounds with different additive types having different molecular structures and properties. The specification details how alternative additives with different chemical characteristics (such as carboxylic acid salts or sulfonates) can achieve similar liquid repulsion effects through different mechanisms, thereby reducing material cost while preserving functional performance
2Ease of manufacture
If polymer amount is reduced to lower cost, then material cost decreases, but liquid barrier properties deteriorate
Solution Approach 1:
The patent changes the formulation parameters by introducing alternative additives that enhance liquid barrier properties without requiring increased polymer content. The specification describes how these additives modify the surface properties or pore characteristics of the nonwoven fabric to improve liquid resistance, allowing cost reduction through lower polymer usage while maintaining or enhancing barrier performance
Solution Approach 2:
The patent creates a composite formulation combining reduced polymer content with alternative additives that provide liquid barrier functionality. The specification details how the combination of lower polymer amounts with specifically selected alternative additives (such as surfactants or surface-modifying agents) creates a cost-effective composite material that achieves the required barrier properties through synergistic effects
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 use of LBEAs in nonwoven fabrics enhances their liquid barrier properties, making them suitable for applications such as facemasks, surgical gowns, and absorbent articles while maintaining cost-effectiveness.
Implementation Method 1
nonwoven fabrics that are hydrophobic and relatively open (e.g., porous) so they are breathable to gases, such as air and water vapor, while resisting penetration by aqueous liquids
Data Source
AI summary
Nonwoven fabrics having liquid barrier properties are provided. The nonwoven fabrics may include one or more nonwoven layers, in which one or more of the nonwoven layers may include a liquid-barrier-enhancing-additive (LBEA) comprising an amide. The nonwoven fabrics may be suitable for use in a wide variety of liquid barrier applications, including facemasks, surgical gowns, surgical drapes, lab coats, and barrier components of absorbent articles (e.g., barrier leg cuffs).