Granted Patent B2

US 8,026,188 · App. 12/491,469 · Granted Sep 27, 2011

Assignee: Techmer PM, LLC

Abstract

Claims (54)

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; and

a lipid ester comprising 10-40 wt. % of the master batch, wherein the fabric has a contact angle ranging from 100° to 125° when measured according to test method ASTM D2578.

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

3. The master batch of claim 1 , where in the lipid ester is a triglyceride ester.

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

5. The master batch of claim 3 , wherein the triglyceride ester includes a fatty acid ranging from C 12 -C 22 .

6. The master batch of claim 3 , wherein the triglyceride ester has a number-averaged molecular weight ranging from 750 to 1000.

7. The master batch of claim 1 , wherein the polymer is a thermoplastic polymer.

8. The master batch of claim 7 , wherein the thermoplastic polymer is selected from a group consisting of polyolefin, polyester, polylactic acid, poly-3-hydroxybutyrate, polyamide, and copolymers thereof.

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

the master batch of claim 1 ; and

a matrix polymer, wherein the fabric has a contact angle ranging from 117-120° when measured according to test method ASTM D2578.

10. A hydrophobic non-woven fabric comprising:

a plurality of fibers comprising the master batch of claim 1 and a matrix polymer; 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).

11. A hydrophobic non-woven fabric comprising:

a plurality of fibers comprising the master batch of claim 1 and a matrix polymer; wherein the non-woven fabric has an alcohol repellency ranging from 10 to 60 when measured according to test method INDA 80.8.

12. A fiber comprising:

a spun-bonded fiber or a meltblown fiber comprising the master batch of claim 1 .

13. A film comprising:

an additive comprising the master batch of claim 1 ; and

a matrix polymer.

14. The film of claim 13 , wherein the matrix polymer comprises a polyethylene, a polypropylene, or a polypropylene copolymer.

15. The film of claim 13 , wherein the master batch includes halogen atoms comprising less than 10 wt. % of the ester.

16. The film of claim 15 , wherein the lipid ester comprises a triglyceride ester.

17. 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 solid, hydrophobic polymer; and

a polymerized, saturated glyceride ester having a number-averaged molecular weight ranging from 500-1200.

18. The master batch of claim 17 , wherein the polymerized, saturated glyceride ester has the structure

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

19. The master batch of claim 18 , wherein R 1 , R 2 , and R 3 comprise a stearic substituent.

20. The master batch of claim 17 , wherein the solid hydrophobic polymer is a thermoplastic polymer.

21. The master batch of claim 17 , wherein the solid hydrophobic polymer is biodegradable or compostable.

22. The master batch of claim 17 , wherein the polymerized, saturated glyceride comprises 10-40 wt. % of the master batch, and wherein the master batch has a hardness ranging from 20 to 100 Shore A when tested according to test method ASTM D2240.

23. The master batch of claim 17 , wherein the polymerized, saturated glyceride comprises 40-95 wt. % of the master batch, and wherein the master batch has a hardness ranging from 1 to 20 Shore A when tested according to test method ASTM D2240.

24. The master batch of claim 17 , wherein the hydrophobic polymer includes an amorphous region or a semi-crystalline region comprising a range from 1 wt. % to 100 wt. % of the hydrophobic polymer when as reported by a content of the master batch.

25. The method for preparing a master batch for use with a fiber, the method comprising:

providing a first polymer; and

compounding a triglyceride ester with the polymer to form the master batch, the triglyceride ester comprising 10-95 wt. % of the master batch, wherein the master batch, which when shaped as a film, has a contact angle ranging from 100° to 125° when measured according to test method ASTM D2578.

26. The method of claim 25 , wherein compounding the triglyceride ester includes meltblending in contact with the first polymer, the triglyceride ester comprising an esterified glycerol backbone having no non-hydrogen substitutents on the backbone.

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

meltblending the master batch prepared by the method of claim 25 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.

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

softening the master batch comprised of material prepared by the method of claim 25 , wherein the triglyceride 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.

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

liquifying the master batch comprised of material prepared by the method of claim 25 , wherein the triglyceride 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.

30. The method of claims 29 , wherein the body comprises a fiber, a fabric, or a film.

Assignments (9)

Continuity (1)