Melt spinning resin composition, manufacturing method for same, and fiber manufacturing method
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Solution Overview
Problem
Existing melt spinning methods face challenges in achieving high production efficiency while preventing thermal degradation and ensuring ease of handling and continuous supply of materials, often requiring complex facilities and significant thermal energy.
Innovation Solution
A resin composition with specific melt viscosity and tensile strength is used, allowing for melt spinning methods like melt blowing and electrospinning, which includes thermoplastic resins and additives to enhance handling and continuous supply, reducing thermal degradation and facility complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional melt spinning methods are used to process large amounts of material, then production efficiency can be improved, but thermal degradation occurs and facility complexity increases
Solution Approach 1:
The invention changes the material form from powder to pre-formed filament, which fundamentally alters the melting process parameters. The filament form allows for controlled melting at lower temperatures and shorter times, reducing thermal degradation while maintaining high production efficiency. The specific viscosity range (250 Pa·s or less at 200°C) is a parameter change that enables efficient processing without excessive thermal exposure.
Solution Approach 2:
The invention performs preliminary action by pre-forming the resin into filament shape before the melting process. This pre-formed filament is then fed into the melting section, eliminating the need for extensive material handling and preparation facilities. The filament is prepared in advance with appropriate viscosity characteristics, allowing the melting section to operate more efficiently with reduced thermal exposure time.
2Ease of manufacture
If conventional melt spinning methods are used, then material can be processed, but operation complexity and facility requirements increase
Solution Approach 1:
The invention segments the manufacturing process into distinct functional sections: a melting section that processes only the filament material, and a spinning section that forms the final fiber. This segmentation allows each section to be optimized independently, with the melting section requiring minimal facilities since it only needs to melt the pre-formed filament rather than process bulk material.
Solution Approach 2:
The invention extracts the material preparation step from the main processing line by using pre-formed filaments. The filament preparation is performed separately beforehand, and only the essential melting and spinning operations remain in the main facility, significantly reducing facility complexity and operational steps.
3Strength
If resin with high melt viscosity is used, then fiber strength can be improved, but spinning efficiency decreases
Solution Approach 1:
The invention identifies and controls the critical parameter of melt viscosity, specifying a range of 250 Pa·s or less at 200°C and shear rate of 0.1 s−1. This parameter optimization enables the resin to achieve adequate fiber strength (10 MPa or more) while maintaining low enough viscosity for efficient spinning operations. The parameter change balances strength requirements with processing efficiency.
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 resin composition enables efficient production of small diameter fibers with improved handling and storage, reducing thermal degradation and facility requirements, while maintaining high production efficiency.
Implementation Method 1
a heating section which melts the material supplied from the supply port, without application of any kneading force
Implementation Method 2
conveying and concurrently cooling the formed material in a filament shape
Data Source
AI summary
The resin composition for melt spinning of the present invention is a filament having a melt viscosity of 250 Pa·s or less at 200° C. and a shear rate of 0.1 s−1 and a tensile strength of 10 MPa or more. The filament can be produced by forming a molten liquid of a resin composition having a melt viscosity of 250 Pa·s or less at 200° C. and a shear rate of 0.1 s−1 into a filament shape to provide a formed material, and conveying and concurrently cooling the formed material. The present invention also provides a resin composition for melt spinning being a filament, and a method for producing fiber using a melt spinning apparatus.