Blended PPS Resin Viscosity for Spunbond Fiber Production
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Solution Overview
Problem
The production of polyphenylene sulfide (PPS) fibers through a spunbond process is hindered by commercially available PPS resins with either too low or too high viscosity, leading to excessive breaks and defects in the fibers.
Innovation Solution
A blended PPS resin with a specific zero shear viscosity at 300° C. of about 21,500 to 28,000 Pa·s is created by combining two commercially available PPS resins, allowing for extended spinning runs with minimal defects and enabling the production of high-quality spunbond fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a low viscosity PPS resin is used, then the resin is easier to process, but it creates excessive breaks in the fibers and defects in the spunbond web
Solution Approach 1:
The patent applies parameter changes by precisely controlling the zero-shear viscosity of PPS resin at 300°C to fall within the range of 21,500 to 28,000 Pa·s. This specific viscosity parameter optimization resolves the contradiction by ensuring the resin has sufficient flowability for processing while maintaining enough structural integrity to prevent fiber breaks and defects during spunbond manufacturing.
2Strength
If a high viscosity PPS resin is used, then the fiber strength is improved, but it creates too much torque in the extruder making the resin unspinnable
Solution Approach 1:
The patent resolves this contradiction by establishing an optimal viscosity parameter range of 21,500 to 28,000 Pa·s at 300°C. This parameter optimization balances the competing requirements: the viscosity is high enough to provide fiber strength and structural integrity, yet low enough to allow proper flow through the extruder and spinneret without excessive torque, thereby maintaining spinnability.
3Adaptability or versatility
If commercially available PPS resins are used, then the material is readily accessible, but the viscosity is either too low or too high for a spunbond process
Solution Approach 1:
The patent addresses this contradiction by implementing precise parameter control of the PPS resin's zero-shear viscosity at 300°C, constraining it to the range of 21,500 to 28,000 Pa·s. This approach allows the use of commercially available PPS materials while achieving the specific viscosity requirements for successful spunbond processing, effectively bridging the gap between material availability and manufacturing precision requirements.
Data Source
AI summary
The present invention is directed to a spunbond fiber comprising polyphenylene sulfide polymer having a zero shear viscosity at 300° C. of about 21,500 to about 28,000 Pa·s.