Nanostructured hydrophobic surface treatment for nonwoven barrier performance
Film-free outercover technology using NANOMYTE® SR-500EC nanostructured coating applied via micro-atomized spray on primed nonwoven substrates. Achieves 100–105° water contact angle, high breathability, fluid barrier up to 62 mbar, and softness below 50 g cup crush at under $80 per thousand square yards.
Overview
This solution replaces plastic film layers in nonwoven outercover applications with a nanostructured organic-inorganic hybrid coating that lowers fiber surface energy to repel liquids while preserving the open pore structure of the substrate. The result is a breathable, soft, and quiet barrier material suitable for hygiene, medical, and industrial nonwoven products. By eliminating the need for a continuous film layer, the technology addresses long-standing trade-offs between fluid barrier performance, breathability, softness, and cost.
Technical specifications
Core chemistry and application:
- NANOMYTE® SR-500EC is a nanostructured organic-inorganic hybrid surface treatment that achieves a water contact angle of 100–105 degrees on fiber surfaces
- Applied via micro-atomized spray coating at ultra-low add-on weights (under 1.0 g/m²), preserving open pore structures and maintaining high air permeability above 5 CFM
- An adhesion-promoting primer is pre-applied to the lightweight synthetic nonwoven substrate (20–30 g/m² PP/PE SMS or carded webs) to ensure robust bonding and prevent chemical rub-off during conversion and use
- Line drying temperatures kept below 100°C to protect substrate integrity
Performance targets:
- Hydrohead barrier performance up to 62 mbar pressure
- Water vapor transmission rate above 2000 g/m²/24hr
- Air permeability above 5 CFM
- Cup crush softness below 50 g
- Tensile strength above 2000 gf/3 in with MD elongation above 5%
- ISO 10993 skin safety compliance
- Finished cost below $80 per thousand square yards
Key advantages over film-based outercovers:
- Eliminates film-induced rustling noise
- Maintains high softness by preserving fiber flexibility
- Scalable roll-to-roll pilot processing capability
- Visual stain masking capability
Technology readiness level
The technology is currently at TRL 3–4, with a defined three-phase validation plan progressing toward TRL 5–6. Phase 1 focuses on substrate selection and primer optimization. Phase 2 validates coating application parameters and confirms barrier, breathability, and softness performance targets. Phase 3 transitions the process to roll-to-roll pilot manufacturing, verifying acoustic performance, visual masking, skin safety, and final cost targets. This staged approach demonstrates a clear commercialization pathway for integration into nonwoven product manufacturing.
About NEI Corporation
Founded in 1997, NEI Corporation is a manufacturer and developer of advanced and specialty materials for industrial applications. The company’s core expertise lies in designing, developing, and producing materials tailored to specific customer needs, which are sold under the registered trademark NANOMYTE®. Their primary product portfolio encompasses functional and protective surface coatings, such as anti-corrosion, self-healing, and scratch-resistant treatments, alongside cathode, anode, and solid electrolyte materials for lithium-ion and sodium-ion batteries. NEI operates out of facilities in New Jersey, utilizing state-of-the-art manufacturing, characterization, and testing equipment to support their material development.
NEI functions as a solutions provider, collaborating closely with a diverse range of partners, including small companies, multinational corporations, government labs, and universities, to integrate their materials into real-world applications. By combining their intellectual property and technical knowledge, they offer comprehensive services such as materials research and development, electrochemical testing, and cell fabrication. Their work addresses critical challenges in energy storage, thermal management, and surface performance, providing customers with custom-synthesized materials that drive innovation and improve product performance across various industrial sectors.
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