Eastman Cyphrex™ microfiberscdn.eastchem.com/cyphrex/PaperConPresentation.pdf · Wet-lap pulp...
Transcript of Eastman Cyphrex™ microfiberscdn.eastchem.com/cyphrex/PaperConPresentation.pdf · Wet-lap pulp...
Eastman Cyphrex™ microfibers designed for wet laid nonwoven & paper
processing
Co-Authors
John Allen, Ph.D (Right)
Senior Research Associate,
Microfiber Applications Development
Keh Dema (Left)
Technology Associate,
Microfiber Applications Development
Topics
Background on microfibers• Characteristics of Cyphrex™ microfibers
• Differences between Cyphrex™ microfibers and most known synthetic fibers
Formation
Strength
Permeability
Attributes of Cyphrex™ microfibers in wet laid nonwovens• Incline wire paper machine (Incline Wire)
• Fourdrinier paper machine (Fourdrinier)
• Compare samples from incline wire and Fourdrinier
Potential applications
Conclusion
Background
Current
non-fibrillated synthetic
fibers for wet laid
minimal wet strength without
bonding agents
minimal dry strength without
bonding agents
cannot be dispersed above 1%
consistency without significant
chemistry
Cyphrex™ can be
conveyed on the wet end of the
machine without bonding agents
dried with enough bond strength to
prepare a roll good
dispersed from 1 to 3.2% consistency
similar to wood pulp
Cyphrex™ microfibers
potential to change everything…
Wet-lap pulp
Media
Wet-laid nonwoven processing
Microfiber precursor
Fiber
processing
Eastman Cyphrex™
microfiber slurry
Eastman CyphrexTM microfibers
50 microns
Novel flat PET microfiber characteristics
1. This novel flat fiber has a ribbon-like cross
section
2. Dimension
- 2.5 microns nominal thickness
- 18 microns nominal width
- 1.5 mm length
3. Supplied as a wet pulp at 50% solids
4. Forms highly uniform wet laid nonwoven papers
- flat microfibers oriented parallel to media
surface
- high inter-fiber surface for bonding
- high sheet surface smoothness
Cyphrex™ microfibers behave differently…
1. Disperses easily in water with minimal shear energy
2. Compatible with traditional paper mill dispersion equipment
3. Accessible dispersion consistencies range up to 3.2%
4. Processes well at desired headbox consistencies for a wide range of forming
equipment – including incline wire, rotoformer, and Fourdrinier
5. Inherent wet green strength allows for producing of 100% PET sheet
6. Enables preparation of synthetic roll good without binder or wet end additives
7. Compatible with typical wet-strength agents – which have also been shown to
significantly improve dry strength as well
8. Blends easily with other fibers – most notably, cellulose, synthetics, and glass
Uniformity attained with 15 gsm novel flat PET
microfiber sheet
Photograph of handsheet
SEM top
view
SEM cross
section
Pulp and paper formation measurement (80 gsm handsheets)
0
0.2
0.4
0.6
0.8
1
Re
lati
ve
Fo
rma
tio
n (
M/K
In
de
x)
NBSK (SR50) 2.5 µ round fiber 4.5 µ round fiber flat PET fiber
NBSK = Northern bleached softwood Kraft wood pulp
Typical strengths of 100% flat PET media(produced on incline wire)
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4
8
12
16
20
0 20 40 60 80 100
Te
ns
ile
, lb
f/in
Basis Weight, gsm
MD Tensile CD Tensile
Effect of wet strength agent on 100% flat PET
media (produced on incline wire)
20
30
40
50
60
70
80
90
20 30 40 50 60 70 80 90 100
Mu
lle
n B
urs
t, p
si
Basis Weight, gsm
without wet strength agent with wet strength agent
Paper properties differ based on machine
configuration (100% flat PET microfibers)
0
4
8
12
16
20
0 25 50 75 100 125
Ten
sil
e, l
bf/
in
Basis Weight, gsm
MD Fourdrinier MD Incline Wire
Blends of novel flat PET microfibers with
cellulose fibers (produced on Fourdrinier)
0
5
10
15
20
25
20 40 60 80 100
MD
Te
ns
ile
, lb
f/in
Basis Weight (gsm)
25% Flat PET 50% Flat PET 100% flat PET
Novel flat PET microfiber improves tear strength(60 gsm media blends with cellulose on Fourdrinier)
0
20
40
60
80
100
120
140
0 20 40 60 80 100 120
MD
Elm
en
do
rf T
ea
r, g
ram
s
%Flat PET microfiber
Novel flat PET microfiber improves permeability(60 gsm media blends with cellulose on Fourdrinier)
0
2
4
6
8
10
12
20 30 40 50 60 70 80 90
Pe
rme
ab
ilit
y, F
3/F
2/m
in
Basis Weight, gsm
100% flat PET flat PET fiber / cellulose blend 100% cellulose
Choice of bonding agent can influence strength (80 gsm flat PET fiber sheets with 10% added binder)
0
5
10
15
20
25
30
35
40
45
MD
Te
ns
ile
, lb
f/in
no binder or calender
acrylic latex
polyurethane dispersion
polyester dispersion
Potential applications
Our fibers enable papermakers to produce high-
performing, high-strength synthetic nonwovens
on standard papermaking equipment.
• High strength paper – packaging, etc.
• Wall cover
Other applications
• Filtration – RO and FO membrane support
• Battery separator – Lithium ion, Lead acid,
etc
Conclusion
Cyphrex™ Flat PET microfibers:
1. Process at consistency similar to wood pulp
2. Can be processed on the flat Fourdrinier, Incline Wire, or Rotoformer
3. Produce highly uniform sheets with high green strength
4. Blend well with other synthetic fibers as well as wood pulp at any ratio
- Preliminary studies suggest that paper made with this synthetic fiber are easily
printable without exotic pretreatment
- The unique properties that this fiber imparts to substrates can create
opportunities for many applications
Next step
Contact us for further discovery, sampling, or development conversations.
Email: [email protected]
Phone number:
1-800-Eastman or 1-423-229-3910
Visit website:
http://www.eastmancyphrex.com