Meltblown Web Using Vis-Broken Polypropylene and PLA
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Solution Overview
Problem
The challenge lies in incorporating sustainable polymers like polylactic acid (PLA) into commercial products while overcoming the difficulties in reclaiming and recycling composite materials made from synthetic and sustainable polymer blends, which leads to increased costs and limited usage.
Innovation Solution
A method of preparing meltblown fibers by blending a polypropylene component with a sustainable polymer component, such as PLA, through vis-breaking, followed by extrusion through a meltblowing die to form a coherent web, which can be thermally bonded, thereby creating a composite sheet structure with improved recyclability and sustainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If composite materials made from synthetic and sustainable polymer blends are used to increase sustainable content, then environmental friendliness is improved, but difficulty in reclaiming and recycling increases
Solution Approach 1:
The bicomponent filament is segmented into distinct sheath and core regions with different polymer compositions (synthetic and sustainable polymers). This segmentation allows each component to be separately identified and reclaimed through selective dissolution or separation processes, resolving the recycling difficulty while maintaining the environmental benefits of sustainable polymer incorporation.
Solution Approach 2:
The patent introduces a selective solvent or reagent as an intermediary that preferentially interacts with one polymer component (e.g., dissolving the sustainable polymer core) while leaving the other component intact. This intermediary enables easy separation and reclaiming of the composite material, addressing the technical contradiction between sustainability and recyclability.
2Object-affected harmful factors
If composite materials made from synthetic and sustainable polymer blends are used to increase sustainable content, then sustainable content is improved, but cost increases
Solution Approach 1:
The patent implements a process where one component of the bicomponent filament (typically the sustainable polymer core) is selectively discarded or dissolved, and the other component (synthetic polymer sheath) is recovered and reused. This recovering process reduces material costs and makes the sustainable composite more economically viable by reusing the expensive synthetic polymer component.
Solution Approach 2:
The patent changes the chemical or physical parameters of one polymer component (e.g., making it soluble in a specific solvent or changing its thermal properties) to enable easy separation and recovery. This parameter change allows for cost-effective processing and reclaiming, reducing the overall manufacturing cost while maintaining high sustainable content.
3Object-affected harmful factors
If PLA is used as a sustainable alternative to petrochemical-derived products, then sustainability is improved, but strength and elongation properties deteriorate
Solution Approach 1:
The patent creates a bicomponent filament where PLA (sustainable polymer) is combined with a synthetic polymer (e.g., polypropylene) having superior mechanical properties. The composite structure allows the PLA core to provide sustainability while the synthetic polymer sheath contributes strength and elongation, effectively resolving the contradiction between sustainability and mechanical performance.
Solution Approach 2:
The patent applies local quality by assigning different functions to different parts of the bicomponent filament: the core region contains the sustainable PLA polymer optimized for eco-friendliness, while the sheath region contains the synthetic polymer optimized for mechanical strength and elongation. This spatial differentiation of material properties allows each component to excel at its intended function.
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
This approach results in meltblown webs with enhanced absorptive and filtration properties, improved bonding between layers in multilayer structures, and increased utility in various applications, including personal care and industrial uses, while reducing environmental impact.
Implementation Method 1
starting fibers comprised of a polypropylene component and a sustainable polymer component are blended under heat to form a molten stream
Implementation Method 2
The molten stream is then subjected to vis-breaking in which the polypropylene component and the sustainable polymer component are vis-broken
Implementation Method 3
The molten stream of the vis-broken polymer components are extruded through a meltblowing die to form a stream of meltblown fibers
Implementation Method 4
the meltblown web may be thermally bonded, such as passing the web through a calender roll
Data Source
AI summary
Process of preparing meltblown fibers that are reclaimed from a starting material of a polypropylene component and a sustainable polymer component is provided. In one aspect, the method includes blending starting fibers of a polypropylene component and a sustainable polymer component under heat to form a molten stream, and then vis-breaking the components to obtain a polymeric blend that is suitable for use in meltblowing applications. The molten stream of the vis-broken polymer components are extruded through a meltblowing die to form a stream of meltblown fibers that is then collected on a collection surface to form a coherent meltblown web. The starting material may be bicomponent filaments having a sheath-core configuration in which the polypropylene component is oriented in the sheath and the sustainable polymer component is oriented in the core of the filaments. The invention is also directed to meltblown fibers and webs prepared from the process.