EP0173333A2 - Procédé d'extrusion et filière d'extrusion ayant un jet d'air central - Google Patents
Procédé d'extrusion et filière d'extrusion ayant un jet d'air central Download PDFInfo
- Publication number
- EP0173333A2 EP0173333A2 EP85110883A EP85110883A EP0173333A2 EP 0173333 A2 EP0173333 A2 EP 0173333A2 EP 85110883 A EP85110883 A EP 85110883A EP 85110883 A EP85110883 A EP 85110883A EP 0173333 A2 EP0173333 A2 EP 0173333A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- thermoplastic material
- extrusion
- high velocity
- thermoplastic
- delivery means
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000001125 extrusion Methods 0.000 title claims abstract description 87
- 238000000034 method Methods 0.000 title claims abstract description 31
- 239000012815 thermoplastic material Substances 0.000 claims abstract description 156
- 239000000835 fiber Substances 0.000 claims abstract description 48
- 229920001169 thermoplastic Polymers 0.000 claims description 39
- 239000004416 thermosoftening plastic Substances 0.000 claims description 37
- 239000000654 additive Substances 0.000 claims description 20
- 230000000996 additive effect Effects 0.000 claims description 20
- 239000000463 material Substances 0.000 claims description 20
- 239000007788 liquid Substances 0.000 claims description 4
- 230000000704 physical effect Effects 0.000 claims description 4
- 239000000155 melt Substances 0.000 claims description 3
- 229920001131 Pulp (paper) Polymers 0.000 claims description 2
- 238000010438 heat treatment Methods 0.000 claims 4
- 239000007789 gas Substances 0.000 description 46
- 239000003570 air Substances 0.000 description 24
- 239000011261 inert gas Substances 0.000 description 21
- 229920000642 polymer Polymers 0.000 description 12
- 238000007664 blowing Methods 0.000 description 9
- -1 polyethylene Polymers 0.000 description 9
- 230000015572 biosynthetic process Effects 0.000 description 7
- 229920001410 Microfiber Polymers 0.000 description 5
- 230000002238 attenuated effect Effects 0.000 description 5
- 239000003658 microfiber Substances 0.000 description 5
- 239000012530 fluid Substances 0.000 description 4
- 238000011160 research Methods 0.000 description 4
- 239000004698 Polyethylene Substances 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 229920000098 polyolefin Polymers 0.000 description 3
- 238000010791 quenching Methods 0.000 description 3
- 230000000171 quenching effect Effects 0.000 description 3
- 239000004743 Polypropylene Substances 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 238000006731 degradation reaction Methods 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- 229920000058 polyacrylate Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 229920002223 polystyrene Polymers 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- 240000000491 Corchorus aestuans Species 0.000 description 1
- 235000011777 Corchorus aestuans Nutrition 0.000 description 1
- 235000010862 Corchorus capsularis Nutrition 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 240000006240 Linum usitatissimum Species 0.000 description 1
- 235000004431 Linum usitatissimum Nutrition 0.000 description 1
- 229920000305 Nylon 6,10 Polymers 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 239000001768 carboxy methyl cellulose Substances 0.000 description 1
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 1
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 125000004494 ethyl ester group Chemical group 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000004750 melt-blown nonwoven Substances 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- 210000003632 microfilament Anatomy 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000011236 particulate material Substances 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 238000012667 polymer degradation Methods 0.000 description 1
- 239000002952 polymeric resin Substances 0.000 description 1
- 229920000193 polymethacrylate Polymers 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 159000000000 sodium salts Chemical class 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D4/00—Spinnerette packs; Cleaning thereof
- D01D4/02—Spinnerettes
- D01D4/025—Melt-blowing or solution-blowing dies
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D4/00—Spinnerette packs; Cleaning thereof
- D01D4/02—Spinnerettes
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
Definitions
- the present invention relates to an extrusion process for producing fibers and nonwoven mats therefrom and to an apparatus used therefor. More particularly, the present invention relates to melt-blowing processes in which a thermoplastic material in molten form is extruded from outlet nozzles such that the molten extrudate merges with the shear layers of a gas jet emanating from a high velocity gas delivery nozzle.
- Nonwoven mats produced by these and other currently known melt blowing processes and the apparatuses used therefor employ an extruder to force a hot melt of thermoplastic material through a row of fine orifices and directly into converging high velocity streams of heated gas, usually air arranged on alternate sides of the extrusion orifices. Fibers of the thermoplastic material are attenuated within the gas stream, the fibers solidifying at a point where the temperature is low enough.
- the present invention provides the potential to at least double the throughput rate realized by currently used melt blowing processes and apparatuses used therefor.
- the apparatus and method of the present invention also permit the formation of composite webs of two or more different polymers.
- the present invention further provides enhancement of quenching of fibers or filaments formed by the method of the present invention due to the closer proximity of the fibers to the quenching air or water vapor used in the process.
- the present invention additionally provides more quiescent exit conditions for extruded thermoplastic material, resulting in less flow disturbance in the downstream region.
- the present invention also permits the entanglement of filaments or fibers in the initial shear region in which turbulence scales are smaller.
- a melt blowing device which includes a die head having at least one centrally disposed high velocity gas or fluid delivery means which is adapted to continuously emit a jet of fluid, preferably a gas.
- the die head also includes at least one chamber for thermoplastic material.
- At least one thermoplastic material delivery means such as one or more thermoplastic material extrusion openings for emitting molten thermoplastic material, are formed in the die head adjacent to the high velocity gas delivery means.
- the centrally disposed high velocity gas delivery means may be placed between or surrounded by the one or more thermoplastic extrusion openings. When more than one thermoplastic extrusion opening is used, more than one thermoplastic material may be supplied to individual extrusion openings from separate chambers.
- Conduit means for fluid communication between the chamber or chambers and each of the thermoplastic material extrusion openings are provided for transfer of the thermoplastic material.
- a means for supplying the thermoplastic material to the chamber or chambers is also provided.
- the thermoplastic material extrusion openings are arranged to direct the extruded thermoplastic material toward the gas jet such that the extruded thermoplastic material is introduced into the shear layers of the gas jet.
- a depositing surface may be provided for collection of streams of attenuated fibers which are formed by the extruded thermoplastic material after contact with the jet of gas.
- the present invention also contemplates a method of producing melt blown fibers and forming a nonwoven mat therefrom according to the steps in which at least one centrally placed high velocity gas stream or jet is formed and at least one stream, generally two or more streams, of a molten thermoplastic material extruded from at least one thermoplastic material extrusion opening or orifice which at least partially surrounds the at least one centrally placed high velocity gas jet is merged with the shear layers of the latter. This results in the formation of at least one stream of fibers of the thermoplastic material which may be directed onto a collecting surface, forming thereby a melt blown nonwoven mat.
- melt blowing processes for producing nonwoven mats known heretofore have extruded fiber-forming thermoplastic polymer resin in molten form through orifices of a heated nozzle into generally two streams of a hot inert gas supplied by jets which at least partially surround the extrusion orifices to attenuate the molten resin as a single stream or row of fibers which are thereafter collected on a receiver to form a nonwoven mat.
- a die head or extrusion head 10 is provided with a chamber 12 for containing a polymeric, generally a thermoplastic material.
- the thermoplastic material may be supplied to chamber 12, generally under pressure, by delivery means or devices 36 such as a supply hopper and an extruder screw or the like.
- the thermoplastic material may be rendered fluid or molten by one or more heaters 39 placed appropriately, such as surrounding the chamber 12, surrounding the hopper and/or between the hopper and the chamber.
- chamber 12 is provided with outlet passages 14 and 16 which permit the flow of molten thermoplastic material from the chamber to a plurality of thermoplastic extrusion outlets, openings or orifices 18 and 20 or a single such opening 19 located in a preferably circular die tip and arranged surrounding a centrally placed means for delivering a generally inert gas as, for example, air, at a high velocity, with an opening such as a nozzle 22 or the like from a source of inert gas 23.
- a generally inert gas as, for example, air
- the air emanating from the high velocity nozzle may be heated by a heater (not shown), appropriately placed, such as in or surrounding the source of inert gas 23 or nozzle 22 itself.
- chamber 12 may be provided with a single outlet (shown in phantom in Figure 1) which branches or forks into two or more passages.
- high velocity generally describes jets having velocities of about 300 to over 2,000 feet/second.
- central or "centrally”, as applied to the gas delivery means or jets, generally includes all situations in which the gas delivery means is surrounded by or arranged between thermoplastic extrusion openings or a portion thereof.
- thermoplastic extrusion opening 19 there may be as few as a single thermoplastic extrusion opening 19 surrounding or at least two thermoplastic extrusion openings 18 and 20 placed around an opening comprising the high velocity gas delivery means or air nozzle 22.
- the high velocity gas delivery means 22 has the form of an elongated opening or slot and a series or individual thermoplastic extrusion openings or slits 18 and 20 are arranged in rows on opposite sides of the gas delivery means 22 as in Figures 3a and 3b.
- the openings 18 and 20 are arranged such that their longitudinal axes form an included angle with the longitudinal axis of the high velocity gas delivery nozzle of about 30 degrees to less than about 90 degrees. As indicated by the embodiment shown in Figure 2, typically this angle is about 60 degrees.
- FIGS 3a-f Some of the arrangements of the centrally placed gas jet and thermoplastic extrusion openings of the present invention, as viewed from the bottom, are shown in Figures 3a-f.
- One preferred arrangement is shown in Figure 3a in which two series of holes 18 and 20 are arranged in rows substantially parallel to and on opposite sides of nozzle 22, formed as a linear, elongated opening or slot.
- Each of the openings in series 18 may be arranged opposite to a corresponding hole in series 20.
- the holes in the two series may have a staggered or skewed relationship with respect to one another.
- Figure 3b depicts an arrangement in which two thermoplastic extrusion openings 18 and 20 take the form of elongated linear openings or slits placed parallel to and on opposite sides of the elongated linear gas nozzle or slot 22.
- the arrangement shown in Figure 3c provides for the inert gas to be emitted from capillary gas nozzles 22 arranged within an elongated slit 19 from which the polymeric material flows.
- nozzles 22 are arranged here linearly along a plane passing through the center and parallel to the elongated edges of the slit, other arrangements, such as an alternating or zigzag arrangement of the air nozzles, are also possible.
- Figure 3d illustrates an extrusion arrangement in which an inert gas nozzle 22, having a circular cross section, is arranged concentrically within a cylindrical opening so that the inner surface of the cylindrical opening and the outer surface of the inert gas nozzle form an annular extrusion opening 19.
- the central air nozzle 22 may have a diameter of up to about two inches.
- the embodiment shown in Figure 3e includes a plurality of thermoplastic polymer extrusion openings 18 and 20 arranged in spaced relationship to one another and to the inert gas nozzle around the circumference of the inert gas nozzle.
- Figure 3f illustrates a plurality of capillary gas nozzles 22 arranged centrally within a thermoplastic extrusion opening 19 having a circular cross section.
- the die head arrangement of the present invention permits molten thermoplastic material to be transferred from chamber 12 through the passages or conduits 14 and 16 to the extrusion openings 19 or 18 and 20, whereupon, as shown in Figure 4, the molten extrudate emerges and contacts the shear layers of the at least one jet of high velocity gas which is being continuously emitted in a stream from the one or more centrally placed nozzles 22.
- the shear layers are considered to be those layers or portions of the inert gas jet located in the peripheral regions of the jet.
- This arrangement results in a plurality of streams, preferably two streams, in the preferred embodiments shown in Figures 3a and 3b of molten extrudate being first attenuated in the peripheral portions or shear layers of the jet or jets, thereby forming filaments or fibers which are mixed and directed to a forming or collecting foraminous surface 37, such as a roll, (shown in Figure 8) or a moving wire placed in the vicinity of the die heads, where the fibers form a matrix or mat 38.
- a forming or collecting foraminous surface 37 such as a roll, (shown in Figure 8) or a moving wire placed in the vicinity of the die heads, where the fibers form a matrix or mat 38.
- the present invention provides the potential to more than double the throughput rate of fiber formation compared to existing processes and apparatus used therefor.
- the filaments formed by the die head of the present invention are attenuated in the shear layers of the high velocity gas stream, these filaments are closer to the air entrained from the atmosphere surrounding the apparatus and quenching becomes much more effective than conventional apparatus in which air jets converge on a centrally emitted stream of thermoplastic material.
- Figures 2 and 5 illustrate in section several configurations of the exit portion of the high velocity gas delivery nozzle 22.
- the wall sections 24 of the outlet portion of the nozzle 22 may be straight and may be arranged substantially parallel to one another, as shown in Figures 5 to 7 or may be arranged to form an included angle with respect to each other, as is shown in Figure 2.
- the included angle formed by the wall sections of the tip of the high velocity gas outlet nozzle is about 60 degrees.
- the tip of the nozzle has a slightly different configuration.
- the tip of the nozzle has a contoured or gradually curving and tapering configuration in which the outlet nozzle walls 26, which are arranged in approximately parallel relationship, taper through a gradual S-shaped configuration 27 to a more constricted nozzle tip 28 in which the walls are approximately parallel or arranged at a slight angle to one another.
- a conduit such as a tube or duct 30, may be placed concentrically within and spaced from the walls 24 of the high velocity gas delivery nozzle.
- the additive delivery conduit may take the form of a duct 30, the outlet end of which is recessed from the outer portion or exit plane 32 formed by the outer surfaces of the high velocity gas delivery nozzle.
- the additive delivery conduit may take the form of a duct 34, the outlet end of which extends from the outer portion or beyond the exit plane of the high velocity gas delivery nozzle.
- the end of the duct may also be arranged with the outlet end having a position between those shown in solid line or in phantom in Figure 6, particularly one in which the outlet end of the duct is flush with plane 32.
- a means may also be provided to move the duct between the two positions illustrated.
- the additive which is introduced into the air stream through the duct may be any gaseous, liquid (such as surfactants or encapsulated liquids), or particulate material (such as a superabsorbent material, i.e., a material capable of absorbing many times its weight of liquid, preferred being materials such as carboxymethyl cellulose and the sodium salt of a cross linked polyacrylate; wood pulp or staple fibers, as, for example, cotton, flax, silk or jute), which is intended to form part of the fibers or the finished web.
- the additive material may be fed from a source located within the extrusion head or remote therefrom.
- the velocities of the inert gas flowing through the high velocity gas delivery nozzle 22 and the mixture of gas and particles flowing through the duct 30 or 34 should be optimized, there is no need that they be the same.
- the material may be fed to the duct by any conventional means using gas as a conveying medium.
- the additive and a suitable fluidizing gas may be mixed and, in some instances, supplied to the duct 22 directly, thus eliminating the use of a duct.
- thermoplastic material may be the same material or, alternatively, materials which differ from one another in their chemical and/or physical properties.
- thermoplastic materials Designated as first, second, ....n thermoplastic materials, where n represents a plurality, the materials may be of the same or different chemical composition or molecular structure and, when of the same molecular structure, may differ in molecular weight or other characteristics which results in differing physical properties.
- the extrusion or die head will be provided with multiple chambers, one for each of the thermoplastic materials, such as first, second, ...n thermoplastic materials, where n represents a plurality. That is, as illustrated in Figure 8, the die head is provided with a first chamber 12a for the first thermoplastic material and a second chamber 12b for the second thermoplastic material, etcetera.
- thermoplastic material chamber 12a communicates with the first extrusion outlet opening 18 by means of the first thermoplastic.material passage 14a, while the second thermoplastic material chamber 12b communicates with the second thermoplastic extrusion opening 20 through the second thermoplastic material passage 16b.
- the extrusion head may be cast either as a single piece or may be formed in multiple component parts, preferably in two generally symmetrical portions 42 and 44 which are suitably clamped, bolted or welded together. Each of these portions may also be formed from separate parts which may also be suitably clamped, bolted or welded together.
- the die head may be provided with a suitable insulating material placed so as to reduce the thermal influences of air surrounding the apparatus or regions of the apparatus. Accordingly, insulation may, for example, be placed between the chambers and, perhaps, the thermoplastic material conduit means 14a and 16b.
- thermoplastic material having one set of properties may be maintained at a first temperature and the second thermoplastic material with a different set of properties may be maintained at a second temperature, etcetera.
- the temperature of the gas and the polymers may be different.
- the heaters themselves and, perhaps, the means of delivering or supplying the thermoplastic material may also be insulated.
- thermoplastic supply or delivery means for the first and second thermoplastic materials
- the apparatus of the present invention which uses two thermoplastic material chambers, includes delivery means which delivers thermoplastic material from a source thereof to the chambers under pressure.
- first and second thermoplastic material chambers separate controls may be provided for supplying the thermoplastic material at different pressures.
- thermoplastic chambers may be formed by any suitable means, such as by appropriately coring or drilling the die head, and the openings and passages or conduits may be drilled.
- Both the high velocity gas delivery nozzle 22 and the extrusion openings 18 and 20 may have dimensions which vary widely depending upon the material being extruded and the concomitant parameters employed, as well as the arrangement of the component parts of the die head.
- Preferred widths of the air nozzle 22 at its effluent end contiguous to the extrusion surface lie in the range of about 0.01 inch to about 1/8 inch but may be larger to permit unimpeded flow of a particulate additive, such as where an additive introduction duct 30, 34 or the like is employed.
- the preferred width of the polymer extrusion openings is about 0.005 inch to about 0.05 inch at their effluent ends contiguous to the polymer extrusion surface. The latter dimension is most preferably about 0.015 inch.
- the dimensions of the thermoplastic extrusion openings may also be made somewhat larger, however, to accommodate the centrally arranged high velocity gas delivery nozzles 22, as shown in Figures 3c, 3d and 3f.
- the present invention also contemplates an embodiment in which the size of each of the first and second thermoplastic material slot openings is adjustable. This may be . accomplished by suitable adjustment means as, for example, slot adjustment struts 46 as shown in Figure 7.
- a nonwoven mat formed from fibers of a polymeric or thermoplastic material may be formed according to the present invention by extruding and collecting multiple streams of thermoplastic material, that is, extruding a first stream of a molten thermoplastic material from one or more first thermoplastic material extrusion openings and concurrently extruding the same or a different molten thermoplastic material from one or more second thermoplastic extrusion openings, which first and second thermoplastic extrusion openings are arranged at least partially surrounding or on opposite sides of the high velocity gas nozzle.
- the extruded thermoplastic material is attenuated to fibers or filaments by a jet or stream of high velocity inert gas passing between the first and second streams of extruded thermoplastic material.
- the fibers form as the first and second thermoplastic material-containing streams merge with the shear layer of the inert gas stream, as shown in Figure 4.
- the fibers are then directed onto a collecting surface, such as a hollow foraminous forming roll or a moving wire belt 37 located about 1 to about 16 inches from the die head.
- the fibrous web or mat 38 is formed largely when the fibers are deposited on the collecting surface. According to the method and apparatus of the present invention, some entanglement of the fibers may occur in the initial shear region where the streams of thermoplatic material merge with the inert gas stream and where the turbulence scales are generally smaller as well as further downstream at the confluence of the two streams of fibers.
- the materials suitable for use in the present invention as polymeric or thermoplastic materials include any materials which are capable of forming fibers after passing through a heated die head and sustaining the elevated temperatures of the die head and of the attenuating air stream for brief periods of time.
- This would include thermoplastic materials such as the polyolefins, particularly polyethylene and polypropylene, polyamides, such as polyhexamethylene adipamide, polyomega-caproamide and polyhexamethylene sebacamide, polyesters, such as the methyl and ethyl esters of polyacrylates and the polymethacrylates and polyethylene terephthalate, cellulose esters, polyvinyl polymers, such as polystyrene, polyacrylonitrile and polytrifluorochloroethylene.
- thermoplastic material Any gas which does not react with the thermoplastic material under the temperature and pressure conditions of the melt blowing process is suitable for use as the inert gas used in the high velocity gas stream which attenuates the thermoplastic materials into fibers or microfibers. Air has been found to be quite suitable for such purposes.
- the fibers may generally be formed in any configuration and diameter commensurate with the shape of the extrusion orifices.
- the process of the present invention is capable of forming coarse fibers, that is, fibers having diameters generally up to about 100 microns and, in some instances, higher, but is generally directed to the formation of fine fibers, known also as microfibers or microfilaments.
- the microfibers produced by the present invention frequently have diameters in the range of about 1 to about 20 microns; however, microfibers may be formed having diameters down to as fine as 0.1 micron.
- thermoplastic material or polymer determines the ability of a given thermoplastic material or polymer to attentuate to a fine fiber.
- the parameters of the extrusion system the nature of the polymeric material, such as the material's molecular weight, melting point, surface tension and viscosity- temperature characteristics, and the pressures and flow rates of air.
- Optimum conditions for any particular thermoplastic material may be achieved by varying such operating parameters as air temperature, nozzle temperature, air velocity or pressure, and the polymer feed rate or ram pressure. These and other variables may be easily determined by one familiar with melt blowing processes.
- the air temperature suitable for attentuating microfibers may be as low as ambient temperature. However, it is ordinarily on the order of at least 200 degrees F above the melting point of the thermoplastic material, although under certain conditions some materials, such as the polyolefins, particularly polyethylene, and polystyrene, require air temperatures on the order of 300 degrees F above the melting or softening points of the thermoplastic materials. When polypropylene is chosen as the polymeric material, a temperature in the range of about 400 to about 700 degrees F is generally used.
- thermoplastic material remains and becomes attentuated in the heated, high velocity inert gas stream is relatively short and there is, therefore, relatively little chance of degradation of the thermoplastic material occurring when elevated temperatures are employed.
- thermoplastic material remains in a heated portion of the die head for a longer period of time than when it is in the high velocity inert gas stream and the susceptibility to degradation increases with both the residence time in the die head and the temperature at which the thermoplastic material is maintained. Therefore, when polymer degradation is being sought, this may be achieved by control of the residence time of the polymer in the die head and the delivery system upstream.
- thermoplastic material extrusion opening or polymer nozzle temperature may be used which is about equal to or as much as 200 degrees Fahrenheit above the air temperature, depending upon the residence time within the heated portion of the die head.
- the temperature of the polymer nozzle is not normally controlled, however, to achieve or maintain a particular temperature. Rather, the temperature of the thermoplastic material extrusion openings is determined in large part from the heat given up by the thermoplastic material passing through the openings and the surrounding air, both that passing through the high velocity gas delivery nozzle and ambient air.
- insulation may be placed around the polymer nozzles, the high velocity gas delivery nozzle, or both.
- the velocity of the heated inert gas stream which depends at least in part on the gas pressure, also varies considerably depending upon the nature of the thermoplastic material.
- thermoplastic materials such as the polyolefins, particularly polyethylene
- air pressures on the order of 1 to 25 psi may be suitable whereas other thermoplastic materials may require 50 psi for fibers of the same diameter and length. Consistant with such variables, the air pressure generally is in the range of 1 to about 60 psig.
- one of the advantages realized with the present invention is the increase in throughput rates. Whereas a standard single row or set of openings will frequently be operated at a rate of 3 pounds/inch/hour with a maximum rate on the order of 25 pounds/inch/hour, the present invention permits a comparable operating rate of 6 pounds/inch/hour up to a rate of about 50 pounds/inch/hour.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
- Nonwoven Fabrics (AREA)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US64566884A | 1984-08-30 | 1984-08-30 | |
US645668 | 1984-08-30 |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0173333A2 true EP0173333A2 (fr) | 1986-03-05 |
EP0173333A3 EP0173333A3 (en) | 1988-03-02 |
EP0173333B1 EP0173333B1 (fr) | 1991-05-22 |
Family
ID=24589967
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP85110883A Expired - Lifetime EP0173333B1 (fr) | 1984-08-30 | 1985-08-29 | Procédé d'extrusion et filière d'extrusion ayant un jet d'air central |
Country Status (7)
Country | Link |
---|---|
EP (1) | EP0173333B1 (fr) |
JP (1) | JPH0660448B2 (fr) |
KR (1) | KR920008961B1 (fr) |
AU (1) | AU576619B2 (fr) |
CA (1) | CA1284411C (fr) |
DE (1) | DE3582908D1 (fr) |
ZA (1) | ZA856523B (fr) |
Cited By (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0272682A2 (fr) * | 1986-12-22 | 1988-06-29 | Kimberly-Clark Corporation | Compositions thermoplastiques à haute capacité d'absorption |
WO1992007121A2 (fr) * | 1990-10-17 | 1992-04-30 | Exxon Chemical Patents Inc. | Filiere de formage par soufflage de matiere fondue |
EP0527489A1 (fr) * | 1991-08-13 | 1993-02-17 | Kuraray Co., Ltd. | Non-tissé à base de polyéthylène térephthalate soufflé et son procédé de production |
WO2000022207A2 (fr) * | 1998-10-01 | 2000-04-20 | The University Of Akron | Procede et appareil permettant de produire des nanofibres |
US6520425B1 (en) | 2001-08-21 | 2003-02-18 | The University Of Akron | Process and apparatus for the production of nanofibers |
US6695992B2 (en) | 2002-01-22 | 2004-02-24 | The University Of Akron | Process and apparatus for the production of nanofibers |
EP1918430A1 (fr) * | 2006-10-18 | 2008-05-07 | Polymer Group, Inc. | Procédé et dispositif pour la fabrication de nanofibres, de non tissés ainsi que les articles les contenant |
KR101282784B1 (ko) | 2011-12-30 | 2013-07-05 | 웅진케미칼 주식회사 | 수직기류를 이용한 단섬유 공급장치 |
CN107614764A (zh) * | 2015-03-26 | 2018-01-19 | 艾姆特克斯股份有限公司 | 纳米纤维制造装置及纳米纤维制造方法 |
CN111542653A (zh) * | 2017-05-22 | 2020-08-14 | M-泰克斯公司 | 纳米纤维制造装置及用于纳米纤维制造装置的喷头 |
IT202000004639A1 (it) * | 2020-03-04 | 2021-09-04 | Cat S R L | Filiera a cuspide per la realizzazione tessuto non tessuto di tipo melt-blown |
EP3875644A1 (fr) * | 2020-03-04 | 2021-09-08 | CAT S.r.l. | Filière à cuspide pour la production de tissu non tissé par fusion-soufflage |
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JP4667668B2 (ja) * | 2001-07-24 | 2011-04-13 | 日本バイリーン株式会社 | エレクトレット化メルトブロー不織布の製造方法及びその製造装置 |
US20040266300A1 (en) * | 2003-06-30 | 2004-12-30 | Isele Olaf Erik Alexander | Articles containing nanofibers produced from a low energy process |
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JP5653775B2 (ja) * | 2011-01-28 | 2015-01-14 | 日本バイリーン株式会社 | 不織布製造装置、不織布の製造方法及び不織布 |
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JP2018187914A (ja) * | 2017-04-28 | 2018-11-29 | 大日本印刷株式会社 | 積層体、表示装置の製造方法およびフレキシブル表示装置 |
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JP7000872B2 (ja) * | 2018-01-18 | 2022-01-19 | 大日本印刷株式会社 | 高落袋強度積層体及び該積層体を用いた包装材料、包装袋 |
JP6894153B2 (ja) * | 2019-07-18 | 2021-06-23 | エム・テックス株式会社 | ナノファイバー製造装置及びナノファイバー製造方法 |
JP6741317B2 (ja) * | 2019-07-18 | 2020-08-19 | エム・テックス株式会社 | ナノファイバー製造装置及びナノファイバー製造方法 |
JP7129077B1 (ja) * | 2022-07-21 | 2022-09-01 | 株式会社化繊ノズル製作所 | メルトブローン装置 |
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US4429001A (en) * | 1982-03-04 | 1984-01-31 | Minnesota Mining And Manufacturing Company | Sheet product containing sorbent particulate material |
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- 1985-08-23 CA CA000489317A patent/CA1284411C/fr not_active Expired - Lifetime
- 1985-08-27 ZA ZA856523A patent/ZA856523B/xx unknown
- 1985-08-28 AU AU46833/85A patent/AU576619B2/en not_active Ceased
- 1985-08-29 DE DE8585110883T patent/DE3582908D1/de not_active Expired - Lifetime
- 1985-08-29 EP EP85110883A patent/EP0173333B1/fr not_active Expired - Lifetime
- 1985-08-30 JP JP60191833A patent/JPH0660448B2/ja not_active Expired - Lifetime
- 1985-08-30 KR KR1019850006302A patent/KR920008961B1/ko not_active IP Right Cessation
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GB609167A (en) * | 1945-03-17 | 1948-09-27 | Bakelite Corp | Manufacture of artificial fibres |
US4100324A (en) * | 1974-03-26 | 1978-07-11 | Kimberly-Clark Corporation | Nonwoven fabric and method of producing same |
US3942723A (en) * | 1974-04-24 | 1976-03-09 | Beloit Corporation | Twin chambered gas distribution system for melt blown microfiber production |
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Cited By (27)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0272682A2 (fr) * | 1986-12-22 | 1988-06-29 | Kimberly-Clark Corporation | Compositions thermoplastiques à haute capacité d'absorption |
EP0272682A3 (fr) * | 1986-12-22 | 1989-01-25 | Kimberly-Clark Corporation | Compositions thermoplastiques à haute capacité d'absorption |
WO1992007121A2 (fr) * | 1990-10-17 | 1992-04-30 | Exxon Chemical Patents Inc. | Filiere de formage par soufflage de matiere fondue |
WO1992007121A3 (fr) * | 1990-10-17 | 1992-08-06 | Exxon Chemical Patents Inc | Filiere de formage par soufflage de matiere fondue |
US5445509A (en) * | 1990-10-17 | 1995-08-29 | J & M Laboratories, Inc. | Meltblowing die |
EP0527489A1 (fr) * | 1991-08-13 | 1993-02-17 | Kuraray Co., Ltd. | Non-tissé à base de polyéthylène térephthalate soufflé et son procédé de production |
US5364694A (en) * | 1991-08-13 | 1994-11-15 | Kuraray Co., Ltd. | Polyethylene terephthalate-based meltblown nonwoven fabric ad process for producing the same |
WO2000022207A2 (fr) * | 1998-10-01 | 2000-04-20 | The University Of Akron | Procede et appareil permettant de produire des nanofibres |
WO2000022207A3 (fr) * | 1998-10-01 | 2000-08-24 | Univ Akron | Procede et appareil permettant de produire des nanofibres |
US6382526B1 (en) | 1998-10-01 | 2002-05-07 | The University Of Akron | Process and apparatus for the production of nanofibers |
US6520425B1 (en) | 2001-08-21 | 2003-02-18 | The University Of Akron | Process and apparatus for the production of nanofibers |
US6695992B2 (en) | 2002-01-22 | 2004-02-24 | The University Of Akron | Process and apparatus for the production of nanofibers |
EP1918430A1 (fr) * | 2006-10-18 | 2008-05-07 | Polymer Group, Inc. | Procédé et dispositif pour la fabrication de nanofibres, de non tissés ainsi que les articles les contenant |
US7666343B2 (en) | 2006-10-18 | 2010-02-23 | Polymer Group, Inc. | Process and apparatus for producing sub-micron fibers, and nonwovens and articles containing same |
US7931457B2 (en) | 2006-10-18 | 2011-04-26 | Polymer Group, Inc. | Apparatus for producing sub-micron fibers, and nonwovens and articles containing same |
US8512626B2 (en) | 2006-10-18 | 2013-08-20 | Polymer Group, Inc. | Process for producing nonwovens and articles containing submicron fibers |
US8962501B2 (en) | 2006-10-18 | 2015-02-24 | Polymer Group, Inc. | Nonwovens and articles containing submicron fibers |
KR101282784B1 (ko) | 2011-12-30 | 2013-07-05 | 웅진케미칼 주식회사 | 수직기류를 이용한 단섬유 공급장치 |
EP3276051A4 (fr) * | 2015-03-26 | 2018-11-14 | M-Techx, Inc. | Dispositif de production de nanofibre et procédé de production de nanofibre |
CN107614764A (zh) * | 2015-03-26 | 2018-01-19 | 艾姆特克斯股份有限公司 | 纳米纤维制造装置及纳米纤维制造方法 |
RU2727941C2 (ru) * | 2015-03-26 | 2020-07-27 | М-ТЕхКс Инк. | Устройство и способ изготовления нановолокна |
US20210025079A1 (en) * | 2015-03-26 | 2021-01-28 | M-Techx Inc. | Apparatus and method for producing nanofiber |
CN107614764B (zh) * | 2015-03-26 | 2022-04-19 | 艾姆特克斯股份有限公司 | 纳米纤维制造装置及纳米纤维制造方法 |
CN111542653A (zh) * | 2017-05-22 | 2020-08-14 | M-泰克斯公司 | 纳米纤维制造装置及用于纳米纤维制造装置的喷头 |
IT202000004639A1 (it) * | 2020-03-04 | 2021-09-04 | Cat S R L | Filiera a cuspide per la realizzazione tessuto non tessuto di tipo melt-blown |
EP3875644A1 (fr) * | 2020-03-04 | 2021-09-08 | CAT S.r.l. | Filière à cuspide pour la production de tissu non tissé par fusion-soufflage |
WO2021176313A1 (fr) * | 2020-03-04 | 2021-09-10 | CAT S.r.L. | Filière à sommet de production de tissu non tissé de fusion-soufflage |
Also Published As
Publication number | Publication date |
---|---|
KR870001915A (ko) | 1987-03-28 |
JPH0660448B2 (ja) | 1994-08-10 |
EP0173333A3 (en) | 1988-03-02 |
DE3582908D1 (de) | 1991-06-27 |
KR920008961B1 (ko) | 1992-10-12 |
AU4683385A (en) | 1986-03-06 |
ZA856523B (en) | 1986-04-30 |
AU576619B2 (en) | 1988-09-01 |
CA1284411C (fr) | 1991-05-28 |
JPS61113809A (ja) | 1986-05-31 |
EP0173333B1 (fr) | 1991-05-22 |
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