Controlled Degradation of Commercial Resin for Meltblown Nonwoven Fabric Sheet Production

Manufacturing meltblown nonwoven fabrics requires special grades of resin with very low viscosity, which are not dealt with so much on market and cost quite high compared to the standard grades. We propose a high-shear rate processing method that can quickly and easily produce such low-viscosity res...

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Autores principales:	Yuya Sasai, Yoshio Iizuka, Kaho Osada, Kentaro Taki
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	meltblown high-shear rate extruder controlled degradation thermal decomposition simulation Organic chemistry QD241-441
Acceso en línea:	https://doaj.org/article/54293877d60245bbbcdd3a4efbe40cd3
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spelling	oai:doaj.org-article:54293877d60245bbbcdd3a4efbe40cd32021-11-25T18:48:01ZControlled Degradation of Commercial Resin for Meltblown Nonwoven Fabric Sheet Production10.3390/polym132238922073-4360https://doaj.org/article/54293877d60245bbbcdd3a4efbe40cd32021-11-01T00:00:00Zhttps://www.mdpi.com/2073-4360/13/22/3892https://doaj.org/toc/2073-4360Manufacturing meltblown nonwoven fabrics requires special grades of resin with very low viscosity, which are not dealt with so much on market and cost quite high compared to the standard grades. We propose a high-shear rate processing method that can quickly and easily produce such low-viscosity resin from the commercial one without using organic peroxides. In this method, we apply high-shear stress to molten resin by using a high-shear extruder, which is a single screw extruder with high screw rotation speed, and the resin is thermally decomposed of its shear-induced heat which is quickly generated. We found that polypropylene with a value of melt flow rate over a thousand, which was required for the meltblown process, was produced from the standard grade with the high-shear extruder at the screw rotation speed of 3600 min<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mrow><mo>−</mo><mn>1</mn></mrow></msup></semantics></math></inline-formula> and the barrel temperature over 300 <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mo>∘</mo></msup></semantics></math></inline-formula>C. Using the degradated polypropylene, a meltblown nonwoven fabric sheet was successfully fabricated. We also developed a numerical simulator of the high-shear extruder which can handle a wide range of the screw rotation speed and barrel temperature by the Nusselt number modulated with the operational conditions. The experimental values of the zero-shear viscosity and temperature at the exit of the extruder agreed well with the simulation results. Our high-shear rate processing method will enable us to quickly and easily produce various meltblown nonwoven fabric sheets at low costs.Yuya SasaiYoshio IizukaKaho OsadaKentaro TakiMDPI AGarticlemeltblownhigh-shear rateextrudercontrolled degradationthermal decompositionsimulationOrganic chemistryQD241-441ENPolymers, Vol 13, Iss 3892, p 3892 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	meltblown high-shear rate extruder controlled degradation thermal decomposition simulation Organic chemistry QD241-441
spellingShingle	meltblown high-shear rate extruder controlled degradation thermal decomposition simulation Organic chemistry QD241-441 Yuya Sasai Yoshio Iizuka Kaho Osada Kentaro Taki Controlled Degradation of Commercial Resin for Meltblown Nonwoven Fabric Sheet Production
description	Manufacturing meltblown nonwoven fabrics requires special grades of resin with very low viscosity, which are not dealt with so much on market and cost quite high compared to the standard grades. We propose a high-shear rate processing method that can quickly and easily produce such low-viscosity resin from the commercial one without using organic peroxides. In this method, we apply high-shear stress to molten resin by using a high-shear extruder, which is a single screw extruder with high screw rotation speed, and the resin is thermally decomposed of its shear-induced heat which is quickly generated. We found that polypropylene with a value of melt flow rate over a thousand, which was required for the meltblown process, was produced from the standard grade with the high-shear extruder at the screw rotation speed of 3600 min<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mrow><mo>−</mo><mn>1</mn></mrow></msup></semantics></math></inline-formula> and the barrel temperature over 300 <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mo>∘</mo></msup></semantics></math></inline-formula>C. Using the degradated polypropylene, a meltblown nonwoven fabric sheet was successfully fabricated. We also developed a numerical simulator of the high-shear extruder which can handle a wide range of the screw rotation speed and barrel temperature by the Nusselt number modulated with the operational conditions. The experimental values of the zero-shear viscosity and temperature at the exit of the extruder agreed well with the simulation results. Our high-shear rate processing method will enable us to quickly and easily produce various meltblown nonwoven fabric sheets at low costs.
format	article
author	Yuya Sasai Yoshio Iizuka Kaho Osada Kentaro Taki
author_facet	Yuya Sasai Yoshio Iizuka Kaho Osada Kentaro Taki
author_sort	Yuya Sasai
title	Controlled Degradation of Commercial Resin for Meltblown Nonwoven Fabric Sheet Production
title_short	Controlled Degradation of Commercial Resin for Meltblown Nonwoven Fabric Sheet Production
title_full	Controlled Degradation of Commercial Resin for Meltblown Nonwoven Fabric Sheet Production
title_fullStr	Controlled Degradation of Commercial Resin for Meltblown Nonwoven Fabric Sheet Production
title_full_unstemmed	Controlled Degradation of Commercial Resin for Meltblown Nonwoven Fabric Sheet Production
title_sort	controlled degradation of commercial resin for meltblown nonwoven fabric sheet production
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/54293877d60245bbbcdd3a4efbe40cd3
work_keys_str_mv	AT yuyasasai controlleddegradationofcommercialresinformeltblownnonwovenfabricsheetproduction AT yoshioiizuka controlleddegradationofcommercialresinformeltblownnonwovenfabricsheetproduction AT kahoosada controlleddegradationofcommercialresinformeltblownnonwovenfabricsheetproduction AT kentarotaki controlleddegradationofcommercialresinformeltblownnonwovenfabricsheetproduction
_version_	1718410711987650560

Controlled Degradation of Commercial Resin for Meltblown Nonwoven Fabric Sheet Production

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