Pfas-free fiber finish for film-free hygiene outercovers

Overview

This technology is a scalable, waterborne, PFAS-free fiber finish engineered for film-free hygiene outercovers. Rather than relying on a continuous film layer to block liquid, the finish modifies individual fiber surfaces to improve liquid holdout and reduce stain visibility while preserving the open pore structure that controls breathability and water vapor transmission.

The approach is designed to meet the growing demand for sustainable, skin-safe, and recyclable hygiene products. By eliminating per- and polyfluoroalkyl substances (PFAS) and avoiding multilayer film constructions, the finish supports simpler product designs that are easier to recycle and more cost-effective to manufacture. The chemistry is tunable, allowing manufacturers to balance barrier performance, tactile softness, drape, low noise, and durability based on end-use requirements.

Technical specifications

Key features:

• Waterborne formulation using low-add-on hydrophobic polymers, bio-derived waxes, or polyolefin-compatible soft binders
• Applied directly to nonwoven fibers via spray, foam, or kiss-roll processing compatible with high-speed nonwoven manufacturing
• Fiber-conformal treatment that modifies surface wetting behavior without forming a continuous film
• Preserves open porosity for air permeability and water vapor transmission rate (WVTR)
• Tunable add-on levels, binder softness, and surface energy to balance liquid holdout, stain masking, softness, drape, and low noise
• PFAS-free chemistry designed for skin-contact safety and recycling compatibility
• Low-cost, bio-derived, or recyclable raw materials

Technology readiness level

This solution is at an early-to-mid stage of development. Future validation will proceed in four phases: initial screening of candidate finishes on representative nonwoven substrates, formulation optimization to balance barrier and comfort properties, benchmarking against film-based controls using standardized tests (hydrohead, strikethrough, WVTR, air permeability, cup crush, tensile strength, stain visibility, and durability), and pilot-scale coating trials to confirm process compatibility, cost, safety, and recycling impact.