Mr. w.john G.McCulloch has long been engaged in the development of meltblown technology at Exxon Corporation before retirement and is now working as a non-woven fabric consultant. Recently he published an article summarizing the origin and development of the meltblown fabric technology. The following paragraph was taken from the second half.
Meltblown fabric fibers are very fine, in addition it has porosity and a certain strength, so the purpose of early opening is battery separators. Exxon (USA) has developed a polypropylene three-layer hot-rolled laminate for this purpose (U.S. Patent No. 4,078,124, etc.). Roy Volkman of Riegel Produucts in the 1970s industrialized production of a polypropylene melt-blown cloth separator for lead-acid maintenance-free batteries. However, the problem of rewetting and the abrasion resistance of the fabric affects its application.
Toa Nenryo has successfully overcome some of these problems with alkaline battery separators (USP 4743494 and 5089360). Entek Co., Ltd. (USP 5230949) produced a web for separators from a high-loaded ultra-high-molecular-weight polyethylene, and the micropores thereon were formed after spinning into a net. Asalu recently announced its intention to open a huge nickel-cadmium battery market with its nylon microfiber web. The demand for long-life battery separators for electric vehicles may create a huge market for melt-blown battery separators.
The microporous and hydrophobic properties of polypropylene webs make it a natural candidate for oil-absorbing materials and wipes. Hydrophilic additives and their handling provide hydrophilicity, which enabled Ergon Nonwovens (USA), Sorbent Products and Kimberly Company to begin manufacturing and selling meltblown webs in the early 1970s. The market continues to grow at a rate of 7% to 8%. The replacement of glass fibers by meltblown fibers in masks and gas masks is now almost complete. Fibreweb (USA) just obtained a patent (USP 5645057) for this purpose, producing fine (0.8-1.3 μm) fiber webs.
In the filtration market, one of the early developments of meltblown webs was cigarette filters. The industrial production of meltblown cigarette filters has not been successful so far, but the development work continues. Meltblown webs have been more successful in other more conventional air and liquid filtration applications. Kimberly-Clark Shipp et al. obtained a patent on a shading filter (USP4714647); Pall recently obtained a patent for a melt-blown filter (USP5582907) that is presumably used for blood filtration; JNIL obtained direct processing of the polymer into a tubular filter product. The material is patented (USP 5,396,642); Akzona has obtained two patents using the Exxon melt-blown process (USP 4666763 and 4247498), which can squeeze solutions and form a thin film that separates blood leukocytes. In addition to the above uses, other landmark developments are as follows:
Kimberly-Clark has made many important innovations. The company's Brock SMS (spunbond/meltblown/spunbond) patents have opened up a huge market for medical applications and surgical coatings. Kimberly-Clark’s patented CoForm technology has been used extensively on rags. 3M (USA) applies a similar idea and has commercialized Thinsulate thermal insulation material. Except for outdoor sportswear and underwater diving suits (recently introduced), it seems that it can also be used as a cable insulation layer.
Biax FiberFilm (USA) used recycled polyester bottles to produce meltblown building insulation; Tandec (Textile and Nonwovens Development Center at the University of Tennessee) has obtained an excellent electrostatic charging patent (USP5401446) that can Filters exhibit higher filtration performance at lower pressure drops; other companies use triboelectric charging, where two different negatively charged polymers are used; BBA (USA) polychlorotrifluoroethylene spray cloth Halar Also open for high temperature filtration applications. Kuss Filtration recently introduced Stratopore PDM fuel filters using three layers of nylon 6 melt blown webs with different fiber sizes.
Fibreweb (USA), on November 7, 1995, disclosed the innovation of liquid crystal meltblowing for high temperature filtration. Freudenberg (Germany) has also announced the use of meltblown webs for cab filtration. Kimberly-Clark is the first company to produce elastic meltblown materials. Toa Nenryo and Kura have used thermoplastic polyurethanes to produce elastic melt-blown fabrics for applications such as hospital gloves. In China, asphalt is now used as a raw material to produce meltblown raw fiber for medium-modulus low-cost carbon fiber. Some companies now test meltblown production of artificial leather. A growing use is to use a thin layer (2.0 g/m2 or less) of meltblown product to adhere to the nonwoven fabric to enhance the shielding and appearance, thereby greatly increasing the value of the base fabric.
The following discussion is the development of meltblowing equipment.
For non-woven products, precision-manufactured and industrially-produced equipment is required, especially for meltblown equipment. Here, the critical parts (dies, nozzles, gas transmission elements, networking equipment) are extremely important. Accurate Products (USA) was the first company (USP4986743) to successfully manufacture a 40-inch molten fountain die in strict accordance with Exxon specifications. Below is an overview of other innovative device developments from which you can learn about the conditions of proprietary meltblown equipment that several major equipment manufacturers have designed and manufactured.
In the early 1990s, JML (USA) successfully changed the conventional meltblown die head and melt-blown the meltblown die onto the substrate cloth by dividing the meltblown die head into several 1~2in parallel units. Each of these parallel devices has an internal valve and the die has a quick change. This has opened up a huge new market for "fat fibred" meltblown fibers (USP5145689, 5692884, etc.). Reifenhauser (Germany) has designed and manufactured an improved structure for meltblowing heads (USP 5248247), and improvements for stretch and heat-setting coarse fiber meltblown webs that claim to be highly productive Structure (USP 569808). The company also designs and sells SMS (spunbond/meltblown/spunbond) production lines.
3M (7 US) obtained patents on the production of high-temperature stable nonwovens equipment. This nonwoven is composed of multiple layers of meltblown microfibers (USP 5232770). Eugene Joseph also published articles on this development. Biax FiberFilm (USA) has designed and sold a meltblown device that employs multiple rows of spinneret holes, which has higher productivity (USP 5,476,616, 4380570).
Kimberly-Clark has obtained a patent for a slot-die for meltblowing that can reduce the clogging of the nozzle (USP472252). Chisso Corporation (Japan) has patented two-component conjugate fiber melt-blown fiber webs and sea-island fiber melt-blown fiber webs (USP 5290626 and 5511960). The patent USP 5711970 obtained by Kimberly-Clark Corporation relates to a device for meltblowing, spunbonding, and CoForm. The device causes the drafting airflow to flow, with the benefit that curled and uncrimped fibers can be produced at lower consumption. This patent appears to be a continuation of USP5695377.
JML recently applied for a new process patent for the online production of SB, MB, SMS, and SMMS. The patent took advantage of the company's earlier patent for a rapid conversion process (Multifil composite yarn system). JML recently applied for a patent, including most of the latest developments (DuraFiber Systems) for forming different fiber patterns on a combination hot melt adhesive die. Tandec has obtained several patents for on-line and off-line processes that make inelastic meltblown webs horizontally elastic. NTC's Mende Corporation has obtained two patents concerning the use of capillary meltblown dies (USP 5017112 and 5171512).
U.S. Patent No. 5,618,566 issued to JML Corporation relates to the structure of a modular melt-blown die head having side-by-side interchangeable components on a manifold. This structure can easily change the die length by adding or subtracting components. Fiberweb has obtained a patent for a process and product that produces high-strength, low-denier and micro-denier fibers with excellent shielding properties (USP 5,793,503). This process utilizes a multi-component die to produce low-orientation, splittable hollow filament fibers. This may be a preparation method for producing microfibers.
Meltblown fabric fibers are very fine, in addition it has porosity and a certain strength, so the purpose of early opening is battery separators. Exxon (USA) has developed a polypropylene three-layer hot-rolled laminate for this purpose (U.S. Patent No. 4,078,124, etc.). Roy Volkman of Riegel Produucts in the 1970s industrialized production of a polypropylene melt-blown cloth separator for lead-acid maintenance-free batteries. However, the problem of rewetting and the abrasion resistance of the fabric affects its application.
Toa Nenryo has successfully overcome some of these problems with alkaline battery separators (USP 4743494 and 5089360). Entek Co., Ltd. (USP 5230949) produced a web for separators from a high-loaded ultra-high-molecular-weight polyethylene, and the micropores thereon were formed after spinning into a net. Asalu recently announced its intention to open a huge nickel-cadmium battery market with its nylon microfiber web. The demand for long-life battery separators for electric vehicles may create a huge market for melt-blown battery separators.
The microporous and hydrophobic properties of polypropylene webs make it a natural candidate for oil-absorbing materials and wipes. Hydrophilic additives and their handling provide hydrophilicity, which enabled Ergon Nonwovens (USA), Sorbent Products and Kimberly Company to begin manufacturing and selling meltblown webs in the early 1970s. The market continues to grow at a rate of 7% to 8%. The replacement of glass fibers by meltblown fibers in masks and gas masks is now almost complete. Fibreweb (USA) just obtained a patent (USP 5645057) for this purpose, producing fine (0.8-1.3 μm) fiber webs.
In the filtration market, one of the early developments of meltblown webs was cigarette filters. The industrial production of meltblown cigarette filters has not been successful so far, but the development work continues. Meltblown webs have been more successful in other more conventional air and liquid filtration applications. Kimberly-Clark Shipp et al. obtained a patent on a shading filter (USP4714647); Pall recently obtained a patent for a melt-blown filter (USP5582907) that is presumably used for blood filtration; JNIL obtained direct processing of the polymer into a tubular filter product. The material is patented (USP 5,396,642); Akzona has obtained two patents using the Exxon melt-blown process (USP 4666763 and 4247498), which can squeeze solutions and form a thin film that separates blood leukocytes. In addition to the above uses, other landmark developments are as follows:
Kimberly-Clark has made many important innovations. The company's Brock SMS (spunbond/meltblown/spunbond) patents have opened up a huge market for medical applications and surgical coatings. Kimberly-Clark’s patented CoForm technology has been used extensively on rags. 3M (USA) applies a similar idea and has commercialized Thinsulate thermal insulation material. Except for outdoor sportswear and underwater diving suits (recently introduced), it seems that it can also be used as a cable insulation layer.
Biax FiberFilm (USA) used recycled polyester bottles to produce meltblown building insulation; Tandec (Textile and Nonwovens Development Center at the University of Tennessee) has obtained an excellent electrostatic charging patent (USP5401446) that can Filters exhibit higher filtration performance at lower pressure drops; other companies use triboelectric charging, where two different negatively charged polymers are used; BBA (USA) polychlorotrifluoroethylene spray cloth Halar Also open for high temperature filtration applications. Kuss Filtration recently introduced Stratopore PDM fuel filters using three layers of nylon 6 melt blown webs with different fiber sizes.
Fibreweb (USA), on November 7, 1995, disclosed the innovation of liquid crystal meltblowing for high temperature filtration. Freudenberg (Germany) has also announced the use of meltblown webs for cab filtration. Kimberly-Clark is the first company to produce elastic meltblown materials. Toa Nenryo and Kura have used thermoplastic polyurethanes to produce elastic melt-blown fabrics for applications such as hospital gloves. In China, asphalt is now used as a raw material to produce meltblown raw fiber for medium-modulus low-cost carbon fiber. Some companies now test meltblown production of artificial leather. A growing use is to use a thin layer (2.0 g/m2 or less) of meltblown product to adhere to the nonwoven fabric to enhance the shielding and appearance, thereby greatly increasing the value of the base fabric.
The following discussion is the development of meltblowing equipment.
For non-woven products, precision-manufactured and industrially-produced equipment is required, especially for meltblown equipment. Here, the critical parts (dies, nozzles, gas transmission elements, networking equipment) are extremely important. Accurate Products (USA) was the first company (USP4986743) to successfully manufacture a 40-inch molten fountain die in strict accordance with Exxon specifications. Below is an overview of other innovative device developments from which you can learn about the conditions of proprietary meltblown equipment that several major equipment manufacturers have designed and manufactured.
In the early 1990s, JML (USA) successfully changed the conventional meltblown die head and melt-blown the meltblown die onto the substrate cloth by dividing the meltblown die head into several 1~2in parallel units. Each of these parallel devices has an internal valve and the die has a quick change. This has opened up a huge new market for "fat fibred" meltblown fibers (USP5145689, 5692884, etc.). Reifenhauser (Germany) has designed and manufactured an improved structure for meltblowing heads (USP 5248247), and improvements for stretch and heat-setting coarse fiber meltblown webs that claim to be highly productive Structure (USP 569808). The company also designs and sells SMS (spunbond/meltblown/spunbond) production lines.
3M (7 US) obtained patents on the production of high-temperature stable nonwovens equipment. This nonwoven is composed of multiple layers of meltblown microfibers (USP 5232770). Eugene Joseph also published articles on this development. Biax FiberFilm (USA) has designed and sold a meltblown device that employs multiple rows of spinneret holes, which has higher productivity (USP 5,476,616, 4380570).
Kimberly-Clark has obtained a patent for a slot-die for meltblowing that can reduce the clogging of the nozzle (USP472252). Chisso Corporation (Japan) has patented two-component conjugate fiber melt-blown fiber webs and sea-island fiber melt-blown fiber webs (USP 5290626 and 5511960). The patent USP 5711970 obtained by Kimberly-Clark Corporation relates to a device for meltblowing, spunbonding, and CoForm. The device causes the drafting airflow to flow, with the benefit that curled and uncrimped fibers can be produced at lower consumption. This patent appears to be a continuation of USP5695377.
JML recently applied for a new process patent for the online production of SB, MB, SMS, and SMMS. The patent took advantage of the company's earlier patent for a rapid conversion process (Multifil composite yarn system). JML recently applied for a patent, including most of the latest developments (DuraFiber Systems) for forming different fiber patterns on a combination hot melt adhesive die. Tandec has obtained several patents for on-line and off-line processes that make inelastic meltblown webs horizontally elastic. NTC's Mende Corporation has obtained two patents concerning the use of capillary meltblown dies (USP 5017112 and 5171512).
U.S. Patent No. 5,618,566 issued to JML Corporation relates to the structure of a modular melt-blown die head having side-by-side interchangeable components on a manifold. This structure can easily change the die length by adding or subtracting components. Fiberweb has obtained a patent for a process and product that produces high-strength, low-denier and micro-denier fibers with excellent shielding properties (USP 5,793,503). This process utilizes a multi-component die to produce low-orientation, splittable hollow filament fibers. This may be a preparation method for producing microfibers.
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