Accessible Requires Authentication Published by De Gruyter September 15, 2021

Effect of Introducing Long Chain Branching on Fiber Diameter and Fiber Diameter Distribution in Melt Blowing Process of Polypropylene

K. Iiba, W. Takarada and T. Kikutani

Abstract

In the melt blowing process, the molten polymers extruded from nozzles are elongated by high-velocity and high-temperature air flow. In this study, with the aim of stabilizing the melt blowing process for producing nonwoven webs with fine diameter fibers, the effect of the control of polymer rheology by the introduction of either low melt flow rate (MFR) polypropylene (PP) or long chain branched PP (LCB-PP) to regular high MFR PP was investigated. Introduction of low MFR PP into regular PP increased shear viscosity and fibers of larger diameter were produced in the melt blowing process, while introduction of low MFR LCB-PP suppressed the elongational viscosity reduction with the increase of strain rate, and eventually spinning was stabilized. It was found that the blending of an optimum amount of LCB-PP to regular PP caused the stabilization of the melt blowing process. As a result, the formation of nonwoven webs consisting of fine fibers of rather uniform diameter distribution could be achieved.


Kozo Iiba, Functional Materials Laboratory, Mitsui Chemicals Inc., 580-32, Nagaura, Sodegaura, Chiba 299-0265 Japan


References

Bagley, E. B., "End Corrections in the Capillary Flow of Polyethylene", Polym. Eng. Sci., 28, 624–627 (1957), DOI:10.1063/1.1722814 Search in Google Scholar

Chen, T., Huang, X., "Study on the Flow Field of the Air Jet from Dual Slot Die in the Melt Blowing Process", Polym. Eng. Sci., 41, 971–976 (2001), DOI:10.1002/pen.10797 Search in Google Scholar

Chhabra, R., Shambaugh, R. L., "Experimental Measurements of Fiber Threadline Vibrations in the Melt-Blowing Process", Ind. Eng. Chem. Res., 35, 4366–4374 (1996), DOI:10.1021/ie960309λ Search in Google Scholar

Cogswell, F. N., "Measuring the Extensional Rheology of Polymer Melts", Trans Soc. Rheol., 16, 383–403 (1972), DOI:10.1122/1.549257 Search in Google Scholar

Drabek, J., Zatloukal, M., "Influence of Long Chain Branching on Fiber Diameter Distribution for Polypropylene Nonwovens Produced by Melt Blown Process", J. Rheol., 63, 519–532 (2019), DOI:10.1122/1.5048585 Search in Google Scholar

Drabek, J., Zatloukal, M., "Meltblown Technology for Production of Polymeric Microfibers/Nanofibers: A Review", Phys. Fluids., 31 (2019), DOI:10.1063/1.5116336 Search in Google Scholar

Ellison, C. J., Phatak, A., Giles, D. W., Macosko, C. W. and Bates, F. S., "Melt Blown Nanofibers: Fiber Diameter Distributions and Onset of Fiber Breakup", Polymer, 48, 3306–3316 (2007), DOI:10.1016/j.polymer.2007.04.005 Search in Google Scholar

Hao, X., Zeng, Y., "A Review on the Studies of Air Flow Field and Fiber Formation Process during Melt Blowing", Ind. Eng. Chem. Res., 58, 11624–11637 (2019), DOI:10.1021/acs.iecr.9b01694 Search in Google Scholar

Harpham, A. S., Shambaugh, R. L., "Flow Field of Practical Dual Rectangular Jets", Ind. Eng. Chem. Res., 35, 3776–3781 (1996), DOI:10.1021/ie960309λ Search in Google Scholar

Kamin, Z., Sarbatly, R., Krishnaiah, D., Tanioka, A. and Takahashi, M., "Melt Blowing Process Conditions for Nanofibers of Polymers for Oil-Water Separation in Marine Oil Spills Clean-up Applications: A Short Review", J. Mech. Eng. Res. Dev., 42, 205–210 (2019), DOI:10.26480/jmerd.05.2019.205.210 Search in Google Scholar

Lawrence, K. D., Lucas, R. T. and Young, J. A.: An Improved Device for the Formation of Superfine, Thermoplastic Fibers, No. NRL-5265, Naval Research LAB, Washington DC (1959), DOI:10.21236/AD0213367 Search in Google Scholar

Lenk, R. S., "Chapter 7 The Hagen-Poiseuille Equation and the Rabinowitsch Correction. The Pressure Drop in Tapered Channels", in Polymer Rheology, Springer, Dordrecht, p. 75–85 (1978), DOI:10.1007/978-94-010-9666-9_7 Search in Google Scholar

McCulloch, J. G., "The History of the Development of Melt Blowing Technology", Int. Nonwovens J., os-°, 1 (1999), DOI:10.1177/1558925099os-800123 Search in Google Scholar

Padmanabhan, M., Macosko, C. W., "Extensional Viscosity from Entrance Pressure Drop Measurements", Rheol. Acta., 36, 144–151 (1997), DOI:10.1007/s003970050031 Search in Google Scholar

Rao, R. S., Shambaugh, R. L., "Vibration and Stability in the Melt Blowing Process", Ind. Eng. Chem. Res., 32, 3100–3111 (1993), DOI:10.1021/ie00024a020 Search in Google Scholar

Ruamsuk, R., Takarada, W. and Kikutani, T., "Fine Filament Formation Behavior of Polymethylpentene and Polypropylene near Spinneret in Melt Blowing Process", Int. Polym. Proc., 31, 217–223 (2016), DOI:10.3139/217.3163 Search in Google Scholar

Sedlacek, T., Zatloukal, M., Filip, P., Boldizar, A. and Saha, P., "On the Effect of Pressure on the Shear and Elongational Viscosities of Polymer Melts", Polym. Eng. Sci., 44, 1328–1337 (2004), DOI:10.1002/pen.20128 Search in Google Scholar

Tan, D. H., Zhou, C., Ellison, C. J., Kumar, S., Macosko, C. W. and Bates, F. S., "Meltblown Fibers: Influence of Viscosity and Elasticity on Diameter Distribution", J. Non-Newtonian Fluid Mech., 165, 892–900 (2010), DOI:10.1016/j.jnnfm.2010.04.012 Search in Google Scholar

Tate, B. D., Shambaugh, R. L., "Modified Dual Rectangular Jets for Fiber Production", Ind. Eng. Chem. Res., 37, 3772–3779 (1998), DOI:10.1021/ie980219a Search in Google Scholar

Tate, B. D., Shambaugh, R. L., "Temperature Fields below Melt-Blowing Dies of Various Geometries", Ind. Eng. Chem. Res., 43, 5405–5410 (2004), DOI:10.1021/ie040066t Search in Google Scholar

Received: 2019-12-04
Accepted: 2021-02-08
Published Online: 2021-09-15
Published in Print: 2021-09-27

© 2021 Walter de Gruyter GmbH, Berlin/Boston, Germany