Development of new materials for spunbond and meltblown

The development of spunbond and meltblown nonwoven technologies has significantly expanded the range of applications for these materials, particularly in industrial textiles. As a result, there's an increasing demand for high-performance polymers that can meet specific requirements such as heat resistance, chemical stability, excellent strength, elasticity, and comfort—especially in medical and food-contact applications. While traditional polymers like PP, PET, PE, PA, and PBT have long been used, many manufacturers are now exploring advanced fiber-forming polymers to enhance performance. These include materials like polyoxymethylene copolymer (POM), cyclic polyolefin copolymer (COC), thermoplastic polyester elastomers (TPEE), and polyphenylene sulfide (PPS). One notable advancement is the use of thermoplastic elastomers in nonwoven production. For example, ExxonMobil’s Vistamaxx™ 2125, recognized with the INDEX 08 Raw Material Award by EDANA, offers superior properties over metallocene plastomers. It features a semi-crystalline structure, good compatibility with OTHER polymers, and ease of processing. This material can be used alone or blended with others, and it performs similarly to PP in cast film processes. Its properties include a density below 1.0 g/cm³, elongation at break over 500%, and tensile strength above 24.5 MPa. Vistamaxx™ is increasingly used in hygienic and filtration products, and it allows for the production of elastic nonwoven fabrics in a single step using various spunbond equipment. China National Bridge Industry Corporation (NBI) has developed a Marnix elastic spunbond fabric using this material, offering stretchability of up to five times and over 90% recovery. It is soft, comfortable, and suitable for medical applications. Dow Chemical introduced INFUSE™ olefin block copolymers, which combine high performance with improved processability. These materials are ideal for elastic films and nonwovens in personal care products like diapers and adult incontinence items. They also offer comfort and flexibility in a wide range of applications. Kraton Polymers’ MD6705 represents another breakthrough, enabling the production of bicomponent elastic nonwovens at full speed on industrial equipment. It allows for high-speed processing and customizable properties, making it suitable for hygiene products, medical devices, and more. In Japan, Idemitsu Kosan developed LMPO, a soft polyolefin with excellent elasticity, thermal stability, and compatibility with PP. It’s ideal for spunbond and meltblown processes and is being tested with Reifenhauser systems. For ultrafine fibers, Ticona’s Celanex 2000-K offers better processability than PET, producing softer and thinner fibers. Eastman’s Eastone S85030 enables the creation of ultrafine island-in-sea or orange petal-type fibers, enhancing the drape and feel of nonwoven fabrics without chemical treatment. In meltblown technology, Toyobo’s Tsunooga fiber offers high strength and durability, suitable for industrial filters. Biax Fiberfilm launched an ultra-high-strength melt-blown material that improves efficiency and performance. Celanese’s Fortron PPS 0203HS provides high-temperature resistance, ideal for harsh environments like flue gas filtration. These innovations continue to push the boundaries of nonwoven technology, opening new possibilities across industries from healthcare to automotive.

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