Abstract:
Melt blown non-woven mats prepared from thermoplastic polymer fibers and substantially completely free of polymer shot are produced at high polymer throughput rates in an improved melt blowing process in which thermoplastic polymer resins, preferably polypropylene, having initial intrinsic viscosities of at least 1.4, are degraded, optionally in the presence of a free radical source compound, to have both reduced intrinsic viscosities and an apparent viscosity in the melt-blowing nozzle orifices of from about 50 to about 300 poise.
Abstract:
A die having a special nose configuration approximating a triangle in cross section is especially suitable for use in a melt-blowing process for making very fine fibers from thermoplastic materials. A plurality of orifices are located in an edge-apex formed at the juncture of two sides of said triangle. The included angle encompassing said edge is within the range of 30* to 90*. The essential feature of said edge is that there are essentially no dead spaces where polymer can collect during the melt-blowing process. Any point on the edge which is more than about 0.002 inches (2 mils) from where the sides make initial contact with said edge is considered to be a dead space. Another feature of the invention involves air slot adjustment means in combination with said die nose.
Abstract:
A HIGHLY TEAR RESISTANT NONWOVEN MAT OF THERMOPLASTIC POLYMER FIBERS IS MADE IN A MELT-BLOWING PROCESS IN WHICH A MOLTEN POLYMERIC RESIN IS EXTRUDED THROUGH A ROW OF DIE OPENINGS INTO A STREAM OF HOT GAS WHICH ATTENUATES THE RESIN INTO FIBERS HAVING DIAMETERS BETWEEN ABOUT 10-40 MICRONS. THE FIBERS ARE COLLECTED ON A CONTINUOUSLY MOVING SURFACE POSITIONED FROM ABOUT 10 TO ABOUT 30 INCHES FROM THE DIE OPENINGS.