Melt blown fiber forming process and method of making fibrous structures

Abstract

A melt blowing process comprising: (a) providing a thermoplastic polymer material that includes at least one or a plurality of polyester polymers and at least one or a combination of different meltable metal phosphinates; and (b) melt blowing the thermoplastic polymer material into at least one fiber or a plurality of fibers, with each fiber having a diameter or thickness that is less than about 10 microns. The metal phosphinate is in an amount that (a) reduces the viscosity of the polyester polymer and (b) functions as a crystallizing agent, which at least promotes crystallization of the polyester polymer, when the thermoplastic polymer material is melt blown into the at least one fiber. Non-woven and woven fibrous structures can be made using fibers made from this process.

1 . The at least one melt blown fiber according to  claim 11 ,
 wherein the metal phosphinate is in an amount that at least promotes crystallization of the polyester polymer, when the thermoplastic polymer material is melt blown into the at least one melt blown fiber.   
     
     
         2 . The at least one melt blown fiber according to  claim 1  in combination with an internal combustion engine, wherein
 the at least one melt blown fiber is disposed adjacent the internal combustion engine such that the at least one melt blown fiber is 
 heated by the internal combustion engine to a temperature equal to or above the glass transition temperature (T g ) of the polyester polymer. 
 
     
     
         3 . A textile product comprising the at least one melt blown fiber according to  claim 1 . 
     
     
         4 . The at least one melt blown fiber according to  claim 11 , wherein the metal phosphinate reduces the viscosity of the polyester polymer and at least promotes crystallization of the polyester polymer, when the thermoplastic polymer material is melt blown into the at least one melt blown fiber. 
     
     
         5 . The at least one melt blown fiber according to  claim 1 , wherein the thermoplastic polymer material comprises in the range of from at least about 0.1 percent by weight of the metal phosphinate up to less than about 20 percent by weight of the metal phosphinate. 
     
     
         6 . (canceled) 
     
     
         7 . The at least one melt blown fiber according to  claim 1 , wherein the at least one melt blown fiber exhibits a low molecular orientation when compared to the same size melt-spun or spunbond fiber made with the same polymer material. 
     
     
         8 . (canceled) 
     
     
         9 . (canceled) 
     
     
         10 . The fibrous structure according to  claim 14 , wherein enough of the polyester polymer in each melt blown fiber crystallizes such that the fibrous structure exhibits less than about 30 percent linear shrinkage when heated to a temperature of about 150° C. for about 4 hours. 
     
     
         11 . At least one melt blown fiber having a diameter of less than about 10 microns and comprising a thermoplastic polymer material comprising at least one polyester polymer and at least one meltable metal phosphinate, wherein said polyester polymer is at least partially crystalline. 
     
     
         12 . The at least one melt blown fiber according to  claim 11 , wherein said melt blown fiber exhibits a low molecular orientation when compared to a melt-spun or spunbond fiber made with the same polymer material. 
     
     
         13 . The at least one melt blown fiber according to  claim 11 , wherein said at least one melt blown fiber exhibits a birefringence of less than or equal to about 0.01. 
     
     
         14 . A fibrous structure comprising a plurality of said at least one melt blown fiber according to  claim 11 . 
     
     
         15 . A fibrous structure comprising a plurality of melt blown fibers, each melt blown fiber comprising a thermoplastic polymer material comprising at least one polyester polymer, and at least one meltable metal phosphinate, wherein the at least one polyester polymer is at least partially crystalline, and the fibrous structure is operatively adapted for use in an environment where the fibrous structure is exposed to temperatures equal to or above the T g  of the at least one polyester polymer. 
     
     
         16 . The fibrous structure according to  claim 14 , wherein enough of the at least one polyester polymer in each melt blown fiber crystallizes such that the fibrous structure exhibits less than about 10 percent linear shrinkage when heated to a temperature of about 150° C. for about 4 hours. 
     
     
         17 . A thermoplastic polymer composition comprising at least one polyester polymer and less than or equal to about 2% by weight of at least one meltable metal phosphinate. 
     
     
         18 . The at least one melt blown fiber according to  claim 12 , wherein said at least one melt blown fiber exhibits a birefringence of less than or equal to about 0.01. 
     
     
         19 . A fibrous structure comprising a plurality of said at least one melt blown fiber according to  claim 12 . 
     
     
         20 . A fibrous structure comprising a plurality of said at least one melt blown fiber according to  claim 13 . 
     
     
         21 . The fibrous structure according to  claim 15 , wherein enough of the at least one polyester polymer in each melt blown fiber crystallizes such that the fibrous structure exhibits less than about 10 percent linear shrinkage when heated to a temperature of about 150° C. for about 4 hours. 
     
     
         22 . The at least one melt blown fiber according to  claim 4 , wherein the at least one melt blown fiber exhibits a low molecular orientation when compared to the same size melt-spun or spunbond fiber made with the same polymer material.