Bio-Based Polyethylene Resin Composition for Fine-Denier Meltblown Fabric
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Solution Overview
Problem
Conventional methods fail to produce meltblown nonwoven fabrics with fine denier and high productivity using plant-derived polyethylene resins, and existing electret materials face issues with low electric charge stability and high environmental impact.
Innovation Solution
A resin composition comprising polyethylene resin, polypropylene resin, and a compatibilizer, optionally with a nitrogen-containing compound and a metal salt of a fatty acid, is used to produce meltblown nonwoven fabrics and electret materials, enhancing productivity and electret performance while reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the spinning temperature is increased to reduce fiber diameter, then the fiber diameter is reduced, but gelation occurs due to cross-linking reaction of molten polyethylene
Solution Approach 1:
A blow agent (nitrogen-containing compound or metal salt of fatty acid) is introduced as an intermediary substance that generates gas bubbles during extrusion, enabling fiber diameter reduction without temperature increase, thereby preventing gelation while achieving fine denier
Solution Approach 2:
The invention changes the processing parameters by introducing a blow agent system that allows fiber diameter control through gas expansion rather than thermal reduction, fundamentally altering the parameter space for fiber formation
2Ease of manufacture
If lower-molecular-weight polyethylene is used to improve spinnability, then spinnability is improved, but fiber strength decreases leading to significant fuzzing
Solution Approach 1:
The invention creates a composite system combining polyethylene resin with blow agents (nitrogen-containing compounds or metal salts of fatty acids), where the composite structure provides both improved spinnability through low molecular weight and sufficient fiber strength through the synergistic effect of gas bubble formation and distribution
Solution Approach 2:
The blow agent acts as an intermediary that enables fine fiber formation without requiring ultra-low molecular weight polyethylene, thereby maintaining fiber strength while achieving good spinnability
3Reliability
If petroleum-derived resins are used to ensure material performance, then material properties are maintained, but environmental impact increases due to decomposition difficulty and fossil resource depletion
Solution Approach 1:
The invention changes the source parameter of the polyethylene resin from petroleum-derived to plant-derived (bio-based), maintaining the chemical structure and performance characteristics while fundamentally altering the environmental footprint and renewability of the material
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the production of meltblown nonwoven fabrics with fine denier and high productivity, and electret materials with improved electric charge stability and reduced environmental impact, achieving superior filtration performance.
Implementation Method 1
a method for producing the electret material
Data Source
AI summary
An object of the present invention is to provide a resin composition that can achieve high productivity and a low environmental impact. The resin composition of the present invention includes a polyethylene resin, a polypropylene resin, and a compatibilizer, in which the polyethylene resin contains a plant-derived polyethylene resin.