Abstract
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Spunbond and meltblown nonwoven fabrics are mainly produced from polypropylene (PP), and their final performance results from the interaction between polymer properties, processing conditions and web structure. The selection and formulation of suitable PP grades are therefore essential for achieving the required processability and fabric properties. This study investigates a reverse engineering-based approach for developing PP formulations adapted to these two processes.
The methodology begins with the characterization of industrial reference PP grades and nonwoven fabrics in order to establish target property profiles for each process. The characterization includes melt flow index (MFI), differential scanning calorimetry (DSC) to determine melting and crystallization behavior and crystallinity, thermogravimetric analysis (TGA) to evaluate thermal stability and residue content, as well as tensile, Charpy impact and air permeability measurements. Several commercial PP grades are then compared with the reference profiles to identify differences in their thermal, rheological and mechanical behavior and to assess their suitability for spunbond and meltblown processing.
Based on these results, selected PP grades will be combined with appropriate masterbatches and additives to develop candidate formulations. These will be evaluated for their processability on spunbond and meltblown lines and for the properties of the resulting fabrics, particularly mechanical performance and air permeability, in order to establish relationships between polymer characteristics, formulation composition, processing conditions and final nonwoven performance.
This approach is expected to provide a rational framework for selecting and formulating PPbased materials according to the requirements of each process. By enabling performance adjustment through formulation, it also supports the broader use of polypropylene nonwovens in advanced technical applications.
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