Starch-Based Fiber Spinning with Sorbitol Plasticizer
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Solution Overview
Problem
Existing technologies face challenges in incorporating starch-based polymeric materials into nonwoven materials and thin fibers due to the high viscosity and rheological characteristics of starch materials, which makes fiber formation difficult and results in inferior physical properties.
Innovation Solution
Development of modified starch-based polymeric materials that can be processed into thin fibers using spunbond, melt blown, and yarn production processes, with specific formulations and processing conditions that control shear viscosity and elongational viscosity to avoid melt flow instability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If starch-based polymeric materials are incorporated into nonwoven materials and thin fibers, then sustainability and biodegradability are enhanced, but high viscosity and rheological characteristics make fiber formation difficult and result in inferior physical properties
Solution Approach 1:
The patent applies parameter changes by carefully controlling processing conditions including temperature (150-250°C), shear rate, and elongational viscosity parameters to enable successful fiber spinning of starch-based materials. The methodology transforms the material's rheological behavior through controlled parameter adjustments, converting an unprocessable high-viscosity material into a spinable formulation without compromising sustainability
Solution Approach 2:
The invention uses composite materials by blending starch-based polymeric materials with thermoplastic polymers to create a hybrid formulation. This composite approach combines the biodegradability and sustainability benefits of starch with the processability and mechanical properties of thermoplastics, resolving the contradiction between environmental performance and manufacturability
2Reliability
If starch-based polymeric materials are used in fiber production, then biodegradability is improved, but high viscosity causes melt flow instability and inferior physical properties
Solution Approach 1:
The patent controls critical parameters including shear viscosity, elongational viscosity, and temperature to prevent melt flow instability during spinning. By maintaining specific viscosity ranges and processing temperatures, the methodology achieves both high biodegradability and superior fiber quality with consistent physical properties
Solution Approach 2:
The invention implements feedback control by monitoring and adjusting processing parameters based on material response during spinning. The methodology uses real-time adjustments to temperature, shear rate, and flow conditions to maintain stable melt flow and produce fibers with consistent quality and physical properties
3Ease of manufacture
If conventional thermoplastic materials are used, then ease of processing and fiber quality are maintained, but sustainability and biodegradability are compromised
Solution Approach 1:
The patent creates composite formulations combining starch-based polymers with thermoplastics in optimized ratios. This composite structure maintains the processing ease and fiber quality of conventional thermoplastics while introducing the sustainability and biodegradability benefits of starch, effectively resolving the environmental trade-off
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 modified starch-based materials can be successfully spun into thin fibers with properties comparable to those of conventional thermoplastic materials, while enhancing the sustainability and biodegradability of the fibers and nonwoven webs.
Implementation Method 1
a thermoplastic polymeric material having a melt flow index configured to plasticize the starch-based polymeric material
Implementation Method 2
processed into thin fibers using spunbond, melt blown, and yarn production processes, with specific formulations and processing conditions that control shear viscosity and elongational viscosity
Data Source
AI summary
Described are starch-based materials, and formulations including such, which can be spun in spunbond, melt blown, yarn, or similar processes. Even with high viscosity resulting from inclusion of the starch-based materials, the formulations can be processed at commercial line speeds, with spinneret shear viscosities of 1000 sec−1, or even up to 4000 sec−1, without onset of melt flow instability. Viscosity and other processing characteristics can be improved by addition of an acid or acid anhydride, and/or by use of sorbitol as the plasticizer, when forming the starch-based material. The starch-based material can be blended with one or more thermoplastic materials, e.g., having higher melt flow index value(s), allowing the blend to be spun. The particular melt flow index characteristics of the thermoplastic diluent material can be selected based on what type of process is being used (e.g., spunbond, melt blown, yarn, etc.).