Polymers & Processes

Olefin Block Copolymers (OBC) deliver a new-to-the-world balance of performance characteristics.  OBCs are based on INSITE™ Technology, catalyst breakthrough combined with Dow’s proprietary manufacturing process, and world class material science which allow new horizons in spunbond nonwoven applications. 

In particular, these resins benefit from chain shuttling technology which enables a heterogeneous distribution of branching along the backbone of the polymer.  This capability allows for olefin elastomers that spin faster and show lower “bundling” tendency than other elastomers.  This presentation will discuss the fundamental structure of these polymers and how they can be used to develop new nonwoven products that deliver conformability and comfort.

New technologies for old lamination processes save money, increase production speeds and provide maximum flexibility.

The purpose of this presentation is to break thru a paradigm.  Laminating nonwovens, textiles, and composites have been done for many years.  Traditional methods include needle punching, ultrasonic’s, roll coating, scatter coating, and flame laminating.  These technologies have served the industry very well for many years.  However, change is in the wind.  Competition is nipping at your heels.  We must constantly be looking at new and different technologies to reduce costs, provide higher production rates, reduce scrap, provide more flexibility, as well as new product possibilities.

All of these variables are real when looking at a technology called uniform fiber deposition.  This is a technology for lamination and composite work utilizing thermoplastics and hot melt polymers.  The technology produces monofilament fibers from the polymers and uses super heated air to elongate the fibers and lay the fibers down in a very controlled fashion.  In many cases, the lamination can be made with the same pull strength, the same shear strength, and reduce adhesive usage as much as 40-50% over current methods. This offers a tremendous cost savings.  Coat weight is very accurate (as tight as 1% cross web).
Fiberization technology benefits include:

1. Variable coat weights on the fly
2. Faster production speeds -line speeds exceeding 2500FPM
3. Intermittent patterning
4. Vary web widths on the fly
5. No burn thru of thin substrates
6. Non contact-will not compress or crush the substrate
7. Provide measured breathability-used in filtration areas
8. Less overall cost
9. Immediate post processing

Specialized applications of this technology include individual strand or individual yarn coating as well as providing composites with thermal or acoustic properties based on precision repeatable air gaps in the substrate composite.
The entire system is PLC based, which provides the upmost in control and can be interfaced with up line control systems for data collection and matching line speeds.