Meltblown Structures Formed by a Robotic and Meltblowing Integrated System: Impact of Process Parameters on Pore Size

Our earlier studies have evaluated the effect of meltblowing process parameters on fiber diameter and orientation distribution. This paper deals with parametric studies evaluating the effect of polymer throughput, attenuating air pressure, take-up speed of the web, fiber stream approach angle, and die-to-collector distance (DCD) on pore sizes and their distribution in meltblown nonwoven webs. Pore sizes and their cumulative frequency are determined by an automated perm porometer. Under the conditions explored, the average pore size of meltblown fabrics decreases significantly when the attenuating air pressure increases. Pore size decreases significantly when the take-up speed of the web increases. As expected, an increase in the polymer throughput increases the average pore size. Increasing the DCD initially decreases, then increases pore size. confirming the existence of different "zones" in the space between the die and collector. An increase in the fiber stream approach angle initially decreases, then significantly increases pore size in the web.