Hydrophobic additive for use with fabric, fiber, and film

1. A master batch for use in preparing a non-woven fabric in order to increase the hydrophobicity of the non-woven fabric, the master batch comprising:

a carrier polymer selected from the group consisting of polyolefin, polyester, polylactic acid, poly-3-hydroxybutyrate, polyamide, and copolymers thereof; and

a lipid ester comprising 10-40 wt. % of the master batch, wherein the lipid ester is a triglyceride ester having a number-averaged molecular weight ranging from 500 to 2000, and, wherein when a fabric is prepared with the master batch, the fabric has a contact angle ranging from 100° to 125° when measured according to test method ASTM D2578 and is hydrophobic, the master batch being in a form of a pellet having a hardness ranging from 20 to 100 Shore A when tested according to test method ASTM D2240.

2. The master batch of claim 1 , wherein the master batch is substantially halogen-free.

3. The master batch of claim 1 , wherein the triglyceride ester includes a fatty acid ranging from C 8 -C 30 .

4. The master batch of claim 1 , further comprising an antioxidant.

5. The master batch of claim 1 , wherein the triglyceride ester has a number-averaged molecular weight ranging from 750 to 1000.

6. The master batch of claim 1 , wherein the carrier polymer secures the triglyceride ester to form the pellet.

7. The master batch of claim 1 , wherein the lipid comprises a fatty acid ester.

8. The master batch of claim 1 , wherein the triglyceride ester comprises saturated stearic acid.

9. A fiber for use in a non-woven fabric, the fiber comprising:

a master batch comprising a carrier polymer and a lipid ester having a number-averaged molecular weight ranging from 500 to 2000, and comprising 10-40 wt. % of the master batch; and

a matrix polymer comprising a polyethylene, a polypropylene, or a polypropylene copolymer;

wherein, when used to make a fabric, the fabric is hydrophobic and has a contact angle ranging from 100-125° when measured according to test method ASTM D2578; and wherein the carrier polymer is selected from the group consisting of polyolefin, polyester, polylactic acid, poly-3-hydroxybutyrate, polyamide, and copolymers thereof.

10. The fiber of claim 9 , wherein the fabric has a contact angle ranging from 117-120° when measured according to test method ASTM D2578.

11. A hydrophobic non-woven fabric comprising:

a plurality of fibers made of the master batch of claim 1 , and a matrix polymer, the fabric having a contact angle ranging from 100° to 125° when measured according to test method ASTM D2578.

12. The hydrophobic non-woven fabric of claim 11 , wherein the non-woven fabric has an alcohol repellency ranging from 10 to 60 when measured according to test method INDA 80.8.

13. The hydrophobic non-woven fabric of claim 11 , wherein the non-woven fabric has a hydrohead ranging from 10 to 20 inches of water when measured according to test method IST 80.6 (0.01).

14. A fiber comprising:

a fiber made of a matrix polymer and a master batch, the master batch comprising a carrier polymer and a lipid ester having a number-averaged molecular weight ranging from 500 to 2000, and comprising 10-40 wt. % of the master batch, wherein the lipid ester is a triglyceride ester, wherein when a fabric is prepared with the master batch, the fabric is hydrophobic and has a contact angle ranging from 100° to 125° when measured according to test method ASTM D2578, wherein the carrier polymer is selected from the group consisting of polyolefin, polyester, polylactic acid, poly-3-hydroxybutyrate, polyamide, and copolymers thereof; and wherein the matrix polymer comprises a polyethylene, a polypropylene, or a polypropylene copolymer.

15. A film comprising:

an additive comprising a master batch comprising a carrier polymer and a lipid ester comprising 10-40 wt. % of the master batch, and

a matrix polymer, the film being hydrophobic and having a contact angle ranging from 100° to 125° when measured according to test method ASTM D2578,

wherein the carrier polymer is selected from the group consisting of polyolefin, polyester, polylactic acid, poly-3-hydroxybutyrate, polyamide, and copolymers thereof; and wherein the matrix polymer comprises a polyethylene, a polypropylene, or a polypropylene copolymer.

16. The film of claim 15 , wherein the matrix polymer comprises a polyethylene, a polypropylene, or a polypropylene copolymer.

17. The film of claim 15 , wherein the master batch includes halogen atoms comprising less than 10 wt. % of the ester.

18. The film of claim 17 , wherein the lipid ester comprises a triglyceride ester.

19. A master batch for use in preparing a hydrophobic non-woven fabric in order to increase the hydrophobicity of the non-woven fabric, the master batch consisting essentially of:

a hydrophobic carrier polymer; and

a saturated glyceride ester having a number-averaged molecular weight ranging from 500 to 2000, wherein when a fabric is prepared with the master batch, the fabric has a contact angle ranging from 100° to 125° when measured according to test method ASTM D2578 and is hydrophobic.

20. The master batch of claim 19 , wherein the saturated glyceride ester is a polymerized, saturated triglyceride ester having the structure

wherein R 1 , R 2 , and R 3 each have a number of carbons ranging from 11-21.

21. The master batch of claim 20 , wherein R1, R2, and R3 comprise a stearic substituent.

22. The master batch of claim 19 , wherein the hydrophobic carrier polymer is selected from the group consisting of polyolefin, polyester, polylactic acid, poly-3-hydroxybutyrate, polyamide, and copolymers thereof.

23. The master batch of claim 19 , wherein the fabric is made up of polymers having a surface energy and the saturated glyceride ester has a surface energy that is greater than the surface energy of the polymers of the fabric.

24. The master batch of claim 19 , wherein the saturated glyceride ester comprises 10-40 wt. % of the master batch and the master batch is in a form of a pellet having a hardness ranging from 20 to 100 Shore A when tested according to test method ASTM D2240.

25. The master batch of claim 19 , wherein the saturated glyceride ester comprises 40-95 wt. % of the master batch, and the master batch is in a form of a pellet having a hardness ranging from 1 to 20 Shore A when tested according to test method ASTM D2240.

26. The master batch of claim 19 , wherein the master batch is substantially halogen free.

27. A method for preparing a solid master batch usable to form a fiber, the method comprising:

providing a first polymer including an amorphous region or a semi-crystalline region comprising a range of 1 wt. % to 100 wt. % of the first polymer; and

blending a lipid ester with the first polymer and solidifying the materials to form the master batch, the lipid ester having a number-averaged molecular weight ranging from 500 to 2000, and comprising 10-95 wt. % of the master batch, wherein the master batch, which when shaped as a film, is hydrophobic and has a contact angle ranging from 100° to 125° when measured according to test method ASTM D2578.

28. The method of claim 27 , wherein compounding the lipid ester includes meltblending in contact with the first polymer, the lipid ester comprising an esterified glycerol backbone having no non-hydrogen substituents on the backbone.

29. A method for forming a hydrophobic fiber, the method comprising:

meltblending the master batch prepared by the method of claim 27 with a second polymer to form a fiber precursor compound; and

forming the fiber precursor compound into the hydrophobic fiber wherein the master batch comprises a range from 1 wt. % to 10 wt. % of the precursor compound.

30. A method for forming a body, the method comprising:

softening the master batch comprised of material prepared by the method of claim 27 , wherein the lipid ester comprises 40 wt. % to 95 wt. % of the master batch;

providing a second polymer;

compacting the master batch with the second polymer to form a precursor compound; and

forming the precursor compound into the body, wherein the master batch comprises a range 0.3 wt. % to 0.5 wt. % of the precursor compound.

31. A method for forming a body, the method comprising:

liquifying the master batch comprised of material prepared by the method of claim 27 , wherein the lipid ester comprises 10 wt. % to 40 wt. % of the master batch;

providing a second polymer;

forming a second polymer into the body; and

coating the body with the liquified master batch, wherein the master batch comprises a range from 1 wt. % to 10 wt. % of the body.

32. The method of claim 31 , wherein the body comprises a fiber, a fabric, or a film.