Compatibilized Polyethylene Resin for Fine Meltblown Electrets
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Solution Overview
Problem
Conventional polyethylene meltblown nonwoven fabrics face challenges in achieving fine fiber diameters and high productivity due to gelation issues, and electret materials made from polyethylene suffer from 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, where the polyethylene resin is partially plant-derived.
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 compatibilizer comprising a block copolymer or graft copolymer containing polyethylene and polypropylene segments is introduced as an intermediary substance between polyethylene and polypropylene. This compatibilizer prevents gelation during high-temperature spinning by mediating the interaction between the two polymers, enabling stable production of fine-diameter fibers without cross-linking reactions
Solution Approach 2:
The invention uses a composite resin composition consisting of polyethylene, polypropylene, and a compatibilizer. This composite material system allows the combination of polyethylene's fine fiber formation capability with polypropylene's structural stability, resolving the gelation issue while achieving reduced fiber diameter
2Ease of manufacture
If lower-molecular-weight polyethylene such as polyethylene wax is used to improve spinnability, then spinnability is improved, but fiber strength decreases leading to significant fuzing
Solution Approach 1:
The invention changes the molecular weight parameters by using conventional polyethylene (weight-average molecular weight 100,000-500,000) instead of low-molecular-weight polyethylene wax, while compensating for viscosity issues through the addition of polypropylene and compatibilizer. This parameter change maintains both spinnability and fiber strength
3Reliability
If petroleum-derived resins are used to ensure equivalent physical properties, then physical properties are maintained, but environmental impact increases due to waste disposal and global warming
Solution Approach 1:
The invention applies local quality by using plant-derived polyethylene specifically for the polyethylene component that requires fine fiber formation, while using polypropylene for structural support. This localized application of bio-based material achieves the desired physical properties while reducing overall environmental impact
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 high electric charge stability and low environmental impact, overcoming the limitations of conventional methods.
Implementation Method 1
a resin composition comprising polyethylene resin, polypropylene resin, and a compatibilizer
Implementation Method 2
the resin composition comprises a compatibilizer
Implementation Method 3
a meltblown nonwoven fabric formed from the polyethylene resin composition
Implementation Method 4
electret materials with high electric charge stability
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.