Polyolefin Nonwoven Fabric Spinning Stability
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Solution Overview
Problem
Conventional polyolefin-based nonwoven fabrics face challenges in reducing fiber diameter while maintaining spinning stability, leading to defects such as end breakage and uneven basis weight.
Innovation Solution
A fibrous nonwoven fabric composed of a resin composition containing high-crystalline and low-crystalline polyolefins, where the half-crystallization time of the resin composition is between 1.2 to 2.0 times that of the high-crystalline polyolefin, with specific elastic modulus ranges and molecular weight distributions to achieve stable spinnability and reduced fiber diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If discharge amount per hole is decreased or spinning speed is increased to reduce fiber diameter, then fiber diameter is reduced, but end breakage occurs frequently and spinning stability deteriorates
Solution Approach 1:
The invention changes the chemical composition parameters of the polyolefin resin by controlling comonomer content (2-10 mass%) and molecular weight distribution (Mw/Mn ratio of 2.0-5.0). This allows reduction of fiber diameter to 3 μm or less while maintaining spinning stability through optimized resin properties that prevent end breakage during high-speed spinning.
Solution Approach 2:
The invention uses a composite polyolefin resin system combining specific comonomer types and molecular weight distributions. This composite approach creates fibers with optimized mechanical properties and spinnability, enabling stable production of ultra-fine fibers without end breakage or roping phenomena.
2Length of moving object
If fiber diameter is reduced to improve wear feeling and hand touch, then texture and comfort are improved, but basis weight becomes uneven and quality defects occur
Solution Approach 1:
The invention optimizes resin parameters including comonomer content (2-10 mass%) and molecular weight distribution (Mw/Mn = 2.0-5.0) to achieve uniform fiber formation. This produces nonwoven fabrics with consistent basis weight and eliminates defects while maintaining ultra-fine fiber diameter for improved hand touch and wear feeling.
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 allows for the reduction of fiber diameter to 0.2 to 1.0 deniers while preserving spinning stability, resulting in a nonwoven fabric with improved strength and hand touch feeling.
Implementation Method 1
a half-crystallization time (t a ) of the high-crystalline polyolefin (A) and a half-crystallization time (t b ) of the low-crystalline polyolefin (B) satisfy a relation of t a ≤t b <2.0t a
Data Source
AI summary
Provided is a fibrous nonwoven fabric including a resin composition (C) containing a high-crystalline polyolefin (A) and a low-crystalline polyolefin (B), wherein a half-crystallization time (tc) of the resin composition (C) is 1.2 to 2.0 times a half-crystallization time (ta) of the high-crystalline polyolefin (A).