Development of new materials for spunbonding and meltblowing
The development of spunbond and meltblown nonwoven technology and the expansion of product applications have promoted the use of high performance polymers to meet the special needs of industrial textiles such as high temperature resistance, chemical resistance, good strength and elasticity, and medical use. Product comfort, safety in contact with food, etc. Many spinning and non-woven equipment manufacturers provide production equipment in addition to traditional PP, PET, COPET, PE, PA, COPA, PBT, PTT, some high-performance fiber-forming high-polymer in spunbond, melt-blown nonwoven products It is also used in China. Such as polyoxymethylene copolymer (POM), cyclic polyolefin copolymer (COC), thermoplastic polyester elastomer (TPE-E), polyphenylene sulfide (PPS) and the like.
(1) Elastomer material
In 2008, the INDEX 08 Raw Materials Award from EDANA was awarded to VistamaxxxTM 2125, developed by ExxonMobil Chemical. VistamaxxTM 2125 is a thermoplastic elastomer that excels in metallocene plastomers. VistamaxxTM has a special semi-crystalline structure that is compatible with other polymers and is easy to process. It can be used as a raw material alone or as a blend with other polymers. The processability when preparing the cast film is very similar to that of PP. The film properties are: density less than 1.0 g/cm3, elongation at break greater than 500%, tensile strength greater than 24.5 MPa, and flexural modulus from 10.5 to 11.2 MPa.
VistamaxxTM is increasingly being used in the nonwovens industry, such as sanitary absorbent materials, medical and filtration materials. In addition, with this elastomeric polymer, spunbond nonwovens manufacturers can produce elastic nonwovens in a single step on a variety of spunbonding equipment. VistamaxxTM can also be used in multi-die production of nonwovens or as one of the layers in multilayer composite nonwovens.
China National Bridge Corporation (NBI) recently invented a Marnix elastic spunbond nonwoven fabric using VistamaxxTM special elastomer, which combines the dual advantages of nonwoven materials and elastic fabrics and can stretch 2 to 5 times. It has an elastic recovery ability of over 90% and is soft to the touch and can be used in medical and health fields. Marnix is ​​degradable and has been patented.
DOW (Dow) Chemical Company of the United States has announced that it will introduce nine development-type olefin block copolymers to the market, which will be sold as INFUSETM olefin block copolymers. INFUSETM olefin block copolymers have a unique block structure that combines high performance with improved processability like never before. Dow's INSITETM technology enables innovation in this material, and INSITETM technology enables olefin elastomers to be used in a wide range of potential applications for flexible materials and a wide range of potential markets. This material provides excellent fit and is ideal for elastic films and elastic nonwovens for diapers and adult incontinence products. Developed olefin block copolymers offer the advantages of processing, compounding and end applications for liquid packaging, adhesives, sanitary and healthcare products, and for demanding comfort products.
Kraton Polymers LLC, the world's leading engineered polymer manufacturer, has introduced the innovation of its latest elastic nonwoven technology, the MD6705. According to Kraton, MD6705 breaks through the process barriers of traditional styrenic block copolymers and now allows processing plants to manufacture two-component elastic nonwovens at full speed on industrial production equipment. Previously, thermoplastic elastomer-based two-component elastic nonwoven fabrics were difficult to produce. Polymers suitable for textiles generally do not have good elasticity, and the unique design of the MD6705 enables processing at industrial production rates and produces good elasticity. On the production lines of the three companies, Hills, Reifenhauser and Oerlikon Neumag with PP, PET and nylon sleeves, the products are shown to be capable of high speed machining. At present, nonwoven fabrics having different weights and sheath-to-core ratios can be produced, and the characteristics of the finished fabric can be easily fine-tuned to meet specific use requirements. Nonwovens made with this new bicomponent fiber technology can be used as elastic materials in personal hygiene products such as diaper belts, diaper waist sticks, side panels for training pants, adult incontinence guards and feminine hygiene Supplies materials, etc. In addition, it can be used in clothing, medical equipment parts, industrial, food service, automotive parts and sporting goods.
Japan's Idemitsu Kosan developed a new soft polyolefin synthesized from propylene and butene using its own single-site catalyst, called LMPO (Table 4). It is said that the nonwoven fabric made of LMPO has excellent elasticity without other support. In addition, the material has high thermal stability, low melt viscosity, odorless, non-blocking, colorless and transparent, compatible with PP, and is suitable for some solvents. In addition, the molecular weight and melt viscosity can be controlled as needed. LMPO is suitable for spunbond and meltblown processes, and Idemitsu Kosan has partnered with Reifenhauser to produce trials on the Reicofil 4 S–Bico system.
Spunbond or meltblown nonwovens based on LMPO will be used primarily in the main part of the diaper (front and side) and are expected to penetrate into medical and sports products. In addition, LMPO can also be used as a polystyrene polymer or additive for hot melts, adhesives, films or other fibers.
(2) Microfiber raw materials
Ticona, Inc. is launching a PBT product, Celanex2000-K, which is planned to replace PET for the production of homogeneous, bicomponent spunbond fibers. According to Ticona, this new PBT shrinks less than conventional PET, not only produces softer and more flexible fibers, but also produces finer fibers than PET, even comparable to fine-denier fibers produced by PP pilot production. . Celenex 2000–K blends with PET to reduce the rigidity of PET fibers and improve their processability.
Eastman Chemical Company's new water-dispersible polymer, the EastONE S85030, can be used to process sea-island or orange-shaped microfibers, giving nonwovens the drape and feel of conventional woven fabrics. This copolyester is mainly used for the processing of filtration and rinsable non-woven fabrics, such as high-strength base fabrics. Ultrafine fibers processed using such copolymers do not require chemical treatment, thereby reducing damage to the fibers. This material is primarily used in melting systems, including spunbond and meltblown nonwoven processes.
(3) High performance meltblown materials
Japan's Toyobo (Toyobo) developed a high-strength melt-blown PE fiber called "Tsunooga" using its patented technology. According to the test, Tsunooga is light in fiber and its cutting resistance is better than that of para-aramid, so it is expected to be used in various industrial fields. In addition, it is also resistant to light, water and chemical stability, and is also suitable for pre-spinning of various colors.
Biax-Fiberfilm, a US meltblown equipment manufacturer, recently announced that they have introduced an ultra-high-strength melt-blown material that allows them to produce the first three processes (S, M, S) in a single process. The finished product, and the product properties, including tensile strength, water repellency and filterability, are the same as SMS. According to reports, this new type of ultra-high-strength melt-blown material is 10 times stronger than conventional melt-blown materials, and has low production cost, small weight and good performance.
Celanese, USA, has introduced a polyphenylene sulfide resin, Fortron PPS 0203HS, for meltblown nonwovens. It is said that this raw material can be processed into a nonwoven fabric on a standard melt-blown equipment which usually uses a PP raw material, but the melting temperature of the melt needs to be 300 to 320 ° C, and the temperature at the spinning needs to be increased.
According to Celanese, the fineness of this PPS meltblown fiber is mostly between 2 and 4 μm, and it is widely distributed from fine to coarse. Due to its high temperature resistance, PPS can be used as a filter material in harsh environments, so it has great development prospects and can be used for flue gas filtration in cement plants and steel plants.
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