Vistamaxx Propylene-based Elastomers

Processing Guidelines for Spunbond Fabrics Introduction

Vistamaxx propylene-based elastomers are a family of polyolefin elastomers exhibiting a wide range of elastic properties along with the capability of processing on equipment designed for polypropylene. These specialty elastomers are produced with ExxonMobil Chemicals proprietary metallocene catalyst technology that allows them to be molecularly designed for specific end-use applications such as spunbond fabrics. Spunbond products can be made from either mono- or bi-component fibers. The elasticity of the fibers can be tailored for specific applications by choosing the appropriate grade, processing conditions and optionally, an additive package. Vistamaxx propylene-based elastomers have a broad melting range, are chemically compatible with other polyolefins and can be thermally bonded at relatively low temperatures to other polyolefin substrates such as polypropylene and polyethylene.

Extruder
Vistamaxx can be processed at conditions very similar to polypropylene. However, the specific output rate (kg/hr/ RPM) of the extruder may be higher than polypropylene due to easier feeding, conveying and melting of the Vistamaxx. In general, a long L/D single-screw extruder (e.g., 30:1 L/D) with a screw having mixing sections is recommended. The actual melt temperature will range from 210 to 215C, but is dependent on the grade selected, screw speed and screw design. For example, with an 80 MFR resin (230C, 2.16 kg): Barrel temperature: 200 (zone 1), 205, 205, 210C (and all down stream zones) Filter: 200 325 mesh screen Adequate cooling at the extruder throat Die temperature: 215C True melt temperature: 210 215C, depending on screw speed and design

Resin characteristics
Vistamaxx propylene-based elastomers are free-flowing pellets designed to be used with conventional resin conveying systems. The elastomers are non-hygroscopic and, therefore, do not require drying before extrusion. Resins designed for high-speed spinning typically have melt flow rates in excess of 20 MFR (230C, 2.16 kg). Vistamaxx propylene-based elastomers have a very narrow molecular weight distribution and, therefore, are very easy to draw down and achieve fine fiber diameter.

Lower MFR grades will require different processing conditions (e.g., 20 MFR, 230 240C).

Spinneret/fiber formation
A die system designed for polypropylene can be used with a typical die hole density of 4000 7000 holes/ meter. However, a lower hole density is preferred to provide better cooling of the fibers. The die hole diameter should be approximately 0.6 mm. The spinneret should be in good condition with no slow holes. Begin at lower output rates and optimize processing conditions before producing fabric at the maximum rate. Air temperature should be set as low as possible (10C) without creating condensation in the forming chamber, and the draw force is increased gradually. For finer fiber, increase draw force until it reaches the maximum cabin pressure.

Vistamaxx propylene-based elastomers take longer to stabilize than polypropylene due primarily to a slower rate of crystallization. Compared to conditions used for processing polypropylene, a colder quench air temperature and higher quench airflow rate is recommended. If the quenching distance adjustment is available, higher quenching distance is recommended. Inadequate fiber quenching may cause fiber bundling, poor formation and difficult release of the fabric from the forming belt.

Web release from forming belt

Low basis weight fibers (e.g., 30 gsm) may be difficult to release from the forming belt and a slip agent may be beneficial. Slip additives can be added in-line with the Vistamaxx. Begin the process with a higher basis weight (e.g., 70 gsm) before going to lower values.

Bonding
Calendering the fabric will bond the fibers, anneal the fabric and make it more elastic. Calender surface temperatures of 82C, with minimum nip pressure, should be sufficient to produce a highly elastic product. The fabric will shrink in the CD direction upon calendering. Lowering the web tension between the calender and the first pull roll of the winder will produce some MD shrinkage and higher elasticity.

Fiber drawing system

A slot drawing system designed for polypropylene is recommended. Systems with individual venturi will require a more aggressive quenching to avoid fiber bundling. There is also an option to produce bi-component fibers with either PP or PE skins. The preferred fiber drawing system should keep the fibers separated while the fiber is being drawn and solidified.

Spunbond fibers emerging from die and forming nonwoven web on moving forming belt

Additives Melt Pump Extruder Resin Filter (Screen Changer) Web Formation To winding and slitting Calender Spinneret Quench Chamber Fiber Drawing Unit

Contact your ExxonMobil Chemical representative for more information.

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