Polyolefin Aqueous Dispersion Coating for Breathable Porous Substrates
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Solution Overview
Problem
Conventional methods for forming breathable articles, such as gloves, often result in products that are either uncomfortable due to poor breathability or lack flexibility and fit, and current technologies struggle to create economically viable, flexible, fiber-lined disposable gloves that provide skin protection and moisture absorption without using powders.
Innovation Solution
A method involving the application of an aqueous dispersion comprising a thermoplastic polymer, specifically polyolefins, to a porous substrate, allowing for the formation of breathable structures with controlled porosity and mechanical properties, enabling the creation of moisture-resistant yet breathable articles using various coating techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastic polymer latex or synthetic rubber membranes are used to create barrier layers for fluid and chemical protection, then barrier properties are improved, but breathability deteriorates causing skin discomfort and perspiration accumulation
Solution Approach 1:
The patent applies porous polyolefin material to create a barrier layer that allows water vapor transmission while blocking liquid fluids and chemicals. The porous structure enables breathability through controlled pore sizes that permit vapor passage but prevent liquid penetration, resolving the contradiction between barrier properties and breathability.
Solution Approach 2:
The patent combines polyolefin porous material with other materials to create a composite structure that integrates both barrier functionality and breathability. This composite approach allows the material to exhibit dual properties: fluid resistance from the polyolefin matrix and vapor permeability from the porous architecture.
2Strength
If thick woven or knit fabric liners are used in gloves, then durability and protection are improved, but flexibility and fit deteriorate
Solution Approach 1:
The patent replaces thick woven or knit fabric liners with thin film-like porous polyolefin material that provides comparable protection while maintaining flexibility. The thin film structure conforms to hand contours and allows natural finger movement, eliminating the stiffness and poor fit associated with thick fabric liners.
Solution Approach 2:
The patent changes the physical parameters of the liner material from thick woven/knit structure to thin porous film structure. This parameter change reduces thickness and increases surface area-to-volume ratio, thereby improving flexibility and fit while maintaining protective functionality through the porous architecture.
3Ease of manufacture
If conventional flat hand-shaped dipping molds are used to manufacture gloves, then manufacturing simplicity is improved, but fit and comfort deteriorate due to poor three-dimensional conformity
Solution Approach 1:
The patent employs three-dimensional hand-shaped molds with accurate curvature and anatomical contours instead of flat dipping molds. This enables the glove material to conform precisely to the complex geometry of the human hand, including finger joints and palm contours, thereby improving fit and comfort while maintaining manufacturing feasibility.
4Object-affected harmful factors
If impervious barrier layers are used to protect against fluids and chemicals, then protection is improved, but moisture absorption and skin health deteriorate due to perspiration trapping
Solution Approach 1:
The patent uses porous polyolefin material that selectively permits water vapor transmission while blocking liquid fluids and chemicals. The pore structure allows perspiration vapor to escape, preventing moisture accumulation and skin problems, while the hydrophobic polyolefin matrix prevents liquid penetration, thus eliminating both harmful 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 solution results in breathable articles that are both comfortable and protective, offering improved fit and flexibility while maintaining moisture resistance, addressing the challenges of breathability and skin protection in disposable gloves.
Implementation Method 1
removing at least a portion of the water
Data Source
Figure 1
AI summary
A method of forming an article that includes applying an aqueous dispersion to a porous substrate, wherein the aqueous dispersion includes a thermoplastic polymer, a dispersing agent, and water. The method includes removing at least a portion of the water, to result in an article formed that is breathable.