No abstract

The meltblowing process employs high-speed hot air jets to attenuate polymer streams injected from a die head. In this study, we examine design strategies to control the air flow field below the polymer injection point to achieve higher fiber attenuation and meltblown webs with smaller fiber diameters. Computational fluid dynamics (CFD) simulations for new die configurations show that vertical or inclined air constrictors around the primary air jets keep the centerline air velocity and temperature at their maximum values for 10–15 mm longer below the die face than the reference die. Polymer streams are kept near their melting temperatures at higher air velocities for a longer period, resulting in higher fiber attenuation. The underlying mechanisms leading to such behavior are discussed. Experimental results show reduction in fiber diameter and pore size, validating the simulation. Improved filtration properties are also obtained from the nonwovens webs.

Solution blowing is one of the most industrially viable processes for mass production of nanofibers without significant change of trade practices. In this work a novel industrially scalable approach to nanofiber production by solution blowing is demonstrated using Biax die. Blends of biopolymer soy protein isolate Clarisoy 100 and poly­(ethylene oxide) (M w = 600 kDa) were solution blown as aqueous solutions using a spinneret with 8 rows with 41 concentric annular nozzles. Nanofiber mats were collected on a drum, and samples with an area of the order of 0.1–1 m2 were formed in about 10 s. Nanofibers were relatively uniform with the diameters of about 500–600 nm. Theoretical aspects of capillary instability, dripping, and fly formation in solution blowing relevant from the experimental point of view are discussed, as well as ways of their prevention are revealed.

Meltblown fibers are typically produced using a die technology based on the slot concept, an extension of the sheet die technology with a series of holes substituting the center rectangular slot of the sheet die. While this prevalent technology has met with considerable success, an economical, facile design would be desirable. In this study a new parallel plate die concept to fabricate micro-meltblown fibers that offers simplicity, ease of use, and low cost was examined. The new die concept had parallel plates forming channels for polymer melt to flow through with a set of air holes surrounding them. This die design produced meltblown fibrous media with fibers in the range of 3-10 lm with pore size between 20 and 60 microns. The underlying mechanisms leading to such large fiber size formation and its implication in air filtration performance has been discussed. While conventional meltblown die generates fibers of smaller diameter and webs with higher filtration efficiency than the parallel plate geometry, design modifications could enhance the parallel plate meltblown die performance and make it a viable alternative. These die adaptations that include reducing air flow resistance, increasing the number of air nozzles around the polymer nozzles, recessing the polymer spinnerets above the die face, and having inclined air channels to increase the drag force on the fibers has been discussed.