Elastic melt-blown nonwoven fabrication of styrene‐ethylene/butylene‐styrene copolymer and polypropylene blends: a study of morphology and properties

Fabrics produced by the melt-blown nonwoven process have the advantage over competing materials of possessing an ultrafine fibrous and porous structure. However, their brittleness and poor toughness restrict their wider application. There is increasing demand for nonwovens that have high stretchability and elasticity while maintaining a melt-blown structure. In this study, polypropylene (PP) and styrene‐ethylene/butylene‐styrene copolymer (SEBS) were blended at different ratios and subsequently used in the melt-blowing process. The morphology of the blends displayed a co-continuous structure when the ratio of SEBS to PP in blends was similar. Furthermore, it was found that all the blends had good spinnability from the melt-blowing process during rheological and thermal properties tests. All the elastic melt-blown nonwovens fabricated in this research had elongations higher than 400% and elastic recoveries higher than 50%, which was indicative of good elasticity. Meanwhile, the nonwovens maintained fine fiber diameters and good filtration properties, in keeping with traditional melt-blown nonwovens.

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

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.

Non-Woven Fabrics Based on Nanocomposite Nylon 6/ZnO Obtained by Ultrasound-Assisted Extrusion for Improved Antimicrobial and Adsorption Methylene Blue Dye Properties

Approximately 200,000 tons of water contaminated with dyes are discharged into effluents annually, which in addition to infectious diseases constitute problems that afflict the population worldwide. This study evaluated the mechanical properties, surface structure, antimicrobial performance, and methylene blue dye-contaminant adsorption using the non-woven fabric manufactured by melt-blowing. The non-woven fabrics are composed of nylon 6 (Ny 6) and zinc oxide nanoparticles (ZnO NPs). The polymer nanocomposites were previously fabricated using variable frequency ultrasound assisted-melt-extrusion to be used in melt-blowing. Energy dispersion spectroscopy (SEM-EDS) images showed a homogeneous dispersion of the ZnO nanoparticles in nylon 6. The mechanical properties of the composites increased by adding ZnO compared to the nylon 6 matrix, and sample Ny/ZnO 0.5 showed the best mechanical performance. All fabric samples exhibited antimicrobial activity against S. aureus and fungus C. albicans, and the incorporation of ZnO nanoparticles significantly improved this property compared to pure nylon 6. The absorption efficiency of methylene blue (MB), during 60 min, for the samples Ny/ZnO 0.05 and Ny/ZnO 0.25 wt%, were 93% and 65%, respectively. The adsorption equilibrium data obeyed the Langmuir isotherm.

A review of processing strategies to generate melt-blown nano/microfiber mats for high-efficiency filtration applications

Protective masks – worn properly - have become the key to wither away the COVID-19 pandemic. Nowadays, the vast majority of these masks are made of nonwoven fabrics. High-quality products have mainly melt-blown filtering layers of nano/microfiber. Melt blowing produces very fine synthetic nonwovens from a wide range of polymers and allows a fair control of the fiber structure and morphology that makes it ideal for filtration purposes. Melt blowing has a high throughput, and the low price of the filter makes these products widely available for civil use. Although melt-blown fiber applications were rapidly growing in the last three decades, we still have limited knowledge on the processing parameters. In this regard, we detailed the melt blowing parameters to obtain a filter media with high particle capturing efficiency and a low-pressure drop. We summarized the melt-blown fiber mat characteristics with specific attention to the pore size, the porosity, the fiber diameter, the fiber packing density and the air permeability desired for highly efficient filtration. Even though we cannot estimate the future social effects and the trauma caused by the current pandemic, and protective masks might remain a part of everyday life for a long while. That also implies that near-future investments in wider manufacturing capacities seem inevitable. This paper also aims to facilitate masks' production with improved filtration efficiency by reviewing the recent developments in melt blowing, the related applications, the effects of processing parameters on the structure and performance of the nonwoven products focusing on the filtration efficiency via knowledge.

Simulation of polymer jet motion during melt blowing with phase field method

In the past two decades, a number of models have been built to simulate the motion of polymer jet during melt blowing. Unfortunately, the complex interaction between polymer jet and air flow field has been rarely reported. In this work, a phase-field method was applied to simulate the coupling effects between polymer and air flow during melt blowing and the computed results were compared with the results of the model built through level-set method and experimental results. Velocity in the x direction, velocity in the y direction, whipping amplitude and diameter of polymer jet were discussed, respectively. It was found that the velocity predicted by the present model was higher than that predicted by the level-set method. However, both of them are close to the experimental value. The calculated final fiber diameter based on the phase-field method is much closer with the experimental value than that based on the level set method. Based on the model, the effect of polymer surface tension and slot angle on the polymer jet velocity were discussed.