Melt blowing

Last updated
Melt blowing process New-ingeo-fiber-grades png.png
Melt blowing process

Melt blowing is a conventional fabrication method of micro- and nanofibers where a polymer melt is extruded through small nozzles surrounded by high speed blowing gas. The randomly deposited fibers form a nonwoven sheet product applicable for filtration, sorbents, apparels and drug delivery systems. The substantial benefits of melt blowing are simplicity, high specific productivity[ jargon ] and solvent-free operation. Choosing an appropriate combination of polymers with optimized rheological and surface properties, scientists have been able to produce melt-blown fibers with an average diameter as small as 36 nm. [1]

Contents

History

During volcanic activity a fibrous material may be drawn by vigorous wind from molten basaltic magma called Pele's hair. [2] The same phenomenon applies for melt blowing of polymers. The first research on melt blowing was a naval attempt in the US to produce fine filtration materials for radiation measurements on drone aircraft in the 1950s. [3] Later on, Exxon Corporation developed the first industrial process based on the melt blowing principle with high throughput levels. [4] China produces 40% of the non-woven fabric in the world with the majority produced in Hebei province (2018). [5]

Polymers

Polymers with thermoplastic behavior are applicable for melt blowing. The main polymer types commonly processed with melt blowing: [6]

Process

Melt blowing is a manufacturing process used to create nonwoven fabrics and materials. It is particularly known for its ability to produce fine fibers, which can be used in various applications. Here's an overview of how melt blowing works: [7]

Uses

Microscopic image of the outer layer of a surgical mask, made from melt blown polymer filaments Vneshnii sloi meditsinskoi maski (poliarizatsiia).jpg
Microscopic image of the outer layer of a surgical mask, made from melt blown polymer filaments

The main uses of melt-blown nonwovens and other innovative approaches are as follows. [8]

Filtration

Nonwoven melt-blown fabrics are porous. As a result, they can filter liquids and gases. Their applications include water treatment, masks, and air-conditioning filters. During the COVID-19 pandemic, the price of meltblown spiked from few thousand USD per ton to approximately 100 thousand USD per ton.

Sorbents

Nonwoven materials can retain liquids several times their own weight. Thus, those made from polypropylene are ideal for collecting oil contamination. [9] [10]

Hygiene products

The high absorption of melt-blown fabrics is exploited in disposable diapers and feminine hygiene products. [11]

Apparels

Melt-blown fabrics have three qualities that help make them useful for clothing, especially in harsh environments: thermal insulation, relative moisture resistance and breathability.

Drug delivery

Melt blowing can produce drug-loaded fibers for controlled drug delivery. [12] The high drug throughput rate (extrusion feeding), solvent-free operation and increased surface area of the product make melt blowing a promising new formulation technique.

Related Research Articles

<span class="mw-page-title-main">Polypropylene</span> Thermoplastic polymer

Polypropylene (PP), also known as polypropene, is a thermoplastic polymer used in a wide variety of applications. It is produced via chain-growth polymerization from the monomer propylene.

<span class="mw-page-title-main">Wood–plastic composite</span> Composite materials made of wood fiber and thermoplastics

Wood-plastic composites (WPCs) are composite materials made of wood fiber/wood flour and thermoplastic(s) such as polythene (PE), polypropylene (PP), polyvinyl chloride (PVC), or polylactic acid (PLA).

<span class="mw-page-title-main">Electrospinning</span>

Electrospinning is a fiber production method that uses electric force to draw charged threads of polymer solutions or polymer melts up to fiber diameters in the order of some hundred nanometers. Electrospinning shares characteristics of both electrospraying and conventional solution dry spinning of fibers. The process does not require the use of coagulation chemistry or high temperatures to produce solid threads from solution. This makes the process particularly suited to the production of fibers using large and complex molecules. Electrospinning from molten precursors is also practiced; this method ensures that no solvent can be carried over into the final product.

<span class="mw-page-title-main">Blow molding</span> Manufacturing process for forming and joining together hollow plastic parts

Blow molding is a manufacturing process for forming hollow plastic parts. It is also used for forming glass bottles or other hollow shapes.

<span class="mw-page-title-main">Nonwoven fabric</span> Sheet of fibers

Nonwoven fabric is a fabric-like material made from staple fibre (short) and long fibres, bonded together by chemical, mechanical, heat or solvent treatment. The term is used in the textile manufacturing industry to denote fabrics, such as felt, which are neither woven nor knitted. Some non-woven materials lack sufficient strength unless densified or reinforced by a backing. In recent years, non-wovens have become an alternative to polyurethane foam.

<span class="mw-page-title-main">Nanofiber</span>

Nanofibers are fibers with diameters in the nanometer range. Nanofibers can be generated from different polymers and hence have different physical properties and application potentials. Examples of natural polymers include collagen, cellulose, silk fibroin, keratin, gelatin and polysaccharides such as chitosan and alginate. Examples of synthetic polymers include poly(lactic acid) (PLA), polycaprolactone (PCL), polyurethane (PU), poly(lactic-co-glycolic acid) (PLGA), poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), and poly(ethylene-co-vinylacetate) (PEVA). Polymer chains are connected via covalent bonds. The diameters of nanofibers depend on the type of polymer used and the method of production. All polymer nanofibers are unique for their large surface area-to-volume ratio, high porosity, appreciable mechanical strength, and flexibility in functionalization compared to their microfiber counterparts.

<span class="mw-page-title-main">Plastic extrusion</span> Melted plastic manufacturing process

Plastics extrusion is a high-volume manufacturing process in which raw plastic is melted and formed into a continuous profile. Extrusion produces items such as pipe/tubing, weatherstripping, fencing, deck railings, window frames, plastic films and sheeting, thermoplastic coatings, and wire insulation.

Olefin fiber is a synthetic fiber made from a polyolefin, such as polypropylene or polyethylene. It is used in wallpaper, carpeting, ropes, and vehicle interiors.

<span class="mw-page-title-main">Nanofabrics</span> Textiles engineered with small particles that give ordinary materials advantageous properties

Nanofabrics are textiles engineered with small particles that give ordinary materials advantageous properties such as superhydrophobicity, odor and moisture elimination, increased elasticity and strength, and bacterial resistance. Depending on the desired property, a nanofabric is either constructed from nanoscopic fibers called nanofibers, or is formed by applying a solution containing nanoparticles to a regular fabric. Nanofabrics research is an interdisciplinary effort involving bioengineering, molecular chemistry, physics, electrical engineering, computer science, and systems engineering. Applications of nanofabrics have the potential to revolutionize textile manufacturing and areas of medicine such as drug delivery and tissue engineering.

<span class="mw-page-title-main">Filler (materials)</span> Particles added to improve its properties

Filler materials are particles added to resin or binders that can improve specific properties, make the product cheaper, or a mixture of both. The two largest segments for filler material use is elastomers and plastics. Worldwide, more than 53 million tons of fillers are used every year in application areas such as paper, plastics, rubber, paints, coatings, adhesives, and sealants. As such, fillers, produced by more than 700 companies, rank among the world's major raw materials and are contained in a variety of goods for daily consumer needs. The top filler materials used are ground calcium carbonate (GCC), precipitated calcium carbonate (PCC), kaolin, talc, and carbon black. Filler materials can affect the tensile strength, toughness, heat resistance, color, clarity, etc. A good example of this is the addition of talc to polypropylene. Most of the filler materials used in plastics are mineral or glass based filler materials. Particulates and fibers are the main subgroups of filler materials. Particulates are small particles of filler that are mixed in the matrix where size and aspect ratio are important. Fibers are small circular strands that can be very long and have very high aspect ratios.

Spinning is a manufacturing process for creating polymer fibers. It is a specialized form of extrusion that uses a spinneret to form multiple continuous filaments.

<span class="mw-page-title-main">Separator (electricity)</span>

A separator is a permeable membrane placed between a battery's anode and cathode. The main function of a separator is to keep the two electrodes apart to prevent electrical short circuits while also allowing the transport of ionic charge carriers that are needed to close the circuit during the passage of current in an electrochemical cell.

<span class="mw-page-title-main">Melt electrospinning</span>

Melt electrospinning is a processing technique to produce fibrous structures from polymer melts for applications that include tissue engineering, textiles and filtration. In general, electrospinning can be performed using either polymer melts or polymer solutions. However, melt electrospinning is distinct in that the collection of the fiber can very focused; combined with moving collectors, melt electrospinning writing is a way to perform 3D printing. Since volatile solvents are not used, there are benefits for some applications where solvent toxicity and accumulation during manufacturing are a concern.

A die in polymer processing is a metal restrictor or channel capable of providing a constant cross sectional profile to a stream of liquid polymer. This allows for continuous processing of shapes such as sheets, films, pipes, rods, and other more complex profiles. This is a continuous process, allowing for constant production, as opposed to a sequential (non-constant) process such as injection molding.

<span class="mw-page-title-main">Hollow fiber membrane</span> Class of artificial membranes containing a semi-permeable hollow fiber barrier

Hollow fiber membranes (HFMs) are a class of artificial membranes containing a semi-permeable barrier in the form of a hollow fiber. Originally developed in the 1960s for reverse osmosis applications, hollow fiber membranes have since become prevalent in water treatment, desalination, cell culture, medicine, and tissue engineering. Most commercial hollow fiber membranes are packed into cartridges which can be used for a variety of liquid and gaseous separations.

Christopher Ward Macosko (1944) is an American chemical engineer and professor emeritus in the department of chemical engineering and materials science at the University of Minnesota. He is internationally known for his work in polymer science and engineering, especially in the areas of rheology and polymer processing. Macosko is an author of more than 500 academic papers, dozens of patents, and two books including the text: "Rheology: Principles, Measurements and Applications". He served as director of the Industrial Partnership for Research in Interfacial and Materials Engineering (IPRIME), a university-industry consortium at the University of Minnesota, from 1999 to 2018. Macosko and his wife Kathleen have been married since 1967 and are long-time residents of Minneapolis. They have four children and 12 grandchildren.

Extrusion welding is one of the processes used to weld thermoplastics and composites, developed in the 1960s as an evolution of hot gas welding. It can be a manual or automated process.

Bicomponent fiber is made of two materials, utilizing desired properties of each material.

Covema srl was a historic Italian company specializing in the design of plastic processing machinery, based in Milan, via Fontana 1. Founded in 1953 by the Terragni brothers, it also included the companies Corima spa, GBF spa, GBF iberica, RIAP srl, FIRS spa, Covepla Spain, Italproducts srl, Omam spa, TPA srl, AGRIPAK srl, Floraplant srl, Interfinance SA, Technical Die spa, Covema SAE. The technology that Covema has developed since the 1950s is merged into Agripak srl based in Milano and managed by the sons of Marco Terragni: Fabio Terragni (president), Patrizia Terragni and Massimo Terragni.

<span class="mw-page-title-main">Medical textiles</span> Textiles for medical and healthcare use

Medical textiles are various fiber-based materials intended for medical purposes. Medical textile is a sector of technical textiles that focuses on fiber-based products used in health care applications such as prevention, care, and hygiene. The spectrum of applications of medical textiles ranges from simple cotton bandages to advanced tissue engineering. Common examples of products made from medical textiles include dressings, implants, surgical sutures, certain medical devices, healthcare textiles, diapers, menstrual pads, wipes, and barrier fabrics.

References

  1. Soltani, Iman; Macosko, Christopher W. (2018). "Influence of rheology and surface properties on morphology of nanofibers derived from islands-in-the-sea meltblown nonwovens". Polymer. 145: 21–30. doi: 10.1016/j.polymer.2018.04.051 . S2CID   139262140.
  2. Shimozuru, D. (1994). "Physical parameters governing the formation of Pele's hair and tears". Bulletin of Volcanology. 56 (3): 217–219. Bibcode:1994BVol...56..217S. doi:10.1007/s004450050030.
  3. Shaumbaugh, R.L. (1988). "A macroscopic view of the melt-blowing process for producing microfibers". Ind. Eng. Chem. Res. 27 (12): 2363–2372. doi:10.1021/ie00084a021.
  4. Ellison CJ, Phatak A, Giles DW, Macosko CW, Bates FS (2007). "Melt blown nanofibers: Fiber diameter distributions and onset of fiber breakup". Polymer. 48 (11): 3306–3316. doi:10.1016/j.polymer.2007.04.005.
  5. "China export credit insurance company releases domestic mask supply and demand risk analysis and outlook". Textile Net China. February 17, 2020.
  6. Dutton, Kathryn C. (2008). "Overview and analysis of the meltblown process and parameters". Journal of Textile and Apparel, Technology and Management. 6.
  7. melt blown nonwoven process Retrieved 7 June 2016.
  8. McCulloch, John G. (1999). "The history of the development of melt blowing technology". International Nonwovens Journal. 8: 1558925099OS–80. doi: 10.1177/1558925099os-800123 .
  9. Wei, Q. F.; Mather, R. R.; Fotheringham, A. F. & Yang, R. D. (2003). "Evaluation of nonwoven polypropylene oil sorbents in marine oil-spill recovery". Marine Pollution Bulletin. 46 (6): 780–783. doi:10.1016/s0025-326x(03)00042-0. PMID   12787586.
  10. Sarbatly R.; Kamin, Z. & Krishnaiah D. (2016). "A review of polymer nanofibres by electrospinning and their application in oil-water separation for cleaning up marine oil spills". Marine Pollution Bulletin. 106 (1–2): 8–16. doi:10.1016/j.marpolbul.2016.03.037. PMID   27016959.
  11. Wehmann, Michael; McCulloch, W. John G. (2012). "Melt blowing technology". In Karger-Kocsis, J. (ed.). Polypropylene: an A-Z reference. Polymer Science and Technology Series. Vol. 2. Springer Science & Business Media. pp. 415–420. doi:10.1007/978-94-011-4421-6_58. ISBN   978-94-010-5899-5.
  12. Balogh, A.; Farkas, B.; Faragó, K.; Farkas, A.; Wagner, I.; Van Assche, I.; et al. (2015). "Melt‐blown and electrospun drug‐loaded polymer fiber mats for dissolution enhancement: A comparative study" (PDF). Journal of Pharmaceutical Sciences. 104 (5): 1767–1776. doi:10.1002/jps.24399. PMID   25761776.