| The primary goal of this research was to determine optimum processing conditions to produce commercially acceptable melt blown (MB) thermoplastic polyurethane (TPU) webs. The 6-inch MB line and the 20-inch wide Accurate Products MB pilot line at the Textiles and Nonwovens Development Center (TANDEC), The University of Tennessee, Knoxville, were utilized for this study.; The MB TPU trials were performed in four different phases: Phase 1 focused on the envelope of the MB operating conditions for different TPU polymers; Phase 2 focused on the production of commercially acceptable MB TPU webs; Phase 3 focused on the optimization of the processing conditions of MB TPU webs, and the determination of the significant relationships between processing parameters and web properties utilizing statistical analyses; Based on the first three phases, a more extensive study of fiber and web formation in the MB TPU process was made and a multi liner regression model for the MB TPU process versus properties was also developed in Phase 4.; In conclusion, the basic MB process was fundamentally valid for the MB TPU process; however, the MB process was more complicated for TPU than PP, because web structures and properties of MB TPUs are very sensitive to MB process conditions: Furthermore, different TPU grades responded very differently to MB processing and exhibited different web structure and properties.; In Phase 3 and Phase 4, small fiber diameters of less than 5mum were produced from TPU237, TPU245 and TPU280 pellets, and the mechanical strengths of MB TPU webs including the tensile strength, tear strength, abrasion resistance and tensile elongation were notably good. In addition, the statistical model showed useful interaction regarding trends for processing parameters versus properties of MB TPU webs. Die and air temperature showed multicollinearity problems and fiber diameter was notably affected by air flow rate, throughput and die/air temperature. It was also shown that most of the MB TPU web properties including mechanical strength, air permeability and fiber diameters were affected by air velocity and die temperature. |
