Journal of Textile Research ›› 2025, Vol. 46 ›› Issue (10): 39-45.doi: 10.13475/j.fzxb.20250202801

• Fiber Materials • Previous Articles     Next Articles

Melt-blown rapid thermal exchange technology enabled construction of lightweight highly elastic thermal insulation batts with performance modulation

GUO Yanna1, HUANG Qiwei1, XU Jinsheng1, DING Chengfeng1, HUANG Wensheng2, LI Kai2, DING Bin3, YU Jianyong3, WANG Xianfeng1,3()   

  1. 1. College of Textiles, Donghua University, Shanghai 201620, China
    2. Shandong Junfu Purification Technology Co., Ltd., Dongying, Shandong 257091, China
    3. Innovation Center for Textile Science and Technology, Donghua University, Shanghai 200051, China
  • Received:2025-02-28 Revised:2025-05-22 Online:2025-10-15 Published:2025-10-15
  • Contact: WANG Xianfeng E-mail:wxf@dhu.edu.cn

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Abstract:

Objective Low-temperature environments pose significant risks to human health, necessitating advanced thermal insulation materials to maintain body temperature. Melt-blown ultra-fine fiber-based materials, characterized by small pore size and high porosity, hold great potential for thermal insulation applications. However, conventional melt-blown materials suffer from complex processing, poor mechanical stability, and insufficient thermal performance. Therefore, developing a simplified method to fabricate melt-blown insulation materials with balanced mechanical properties and excellent thermal insulation is critical.

Method Polypropylene (PP)-based lightweight elastic fiber batts were produced via melt-blown nonwoven technology. A novel approach was employed to control the melt-environment heat exchange rate by adjusting hot-air temperature (140-200 ℃) during processing, enabling the fabrication of batts with tunable loftiness. The influence of temperature on fiber morphology, crystallinity, mechanical resi-lience, and thermal insulation was systematically studied. This strategy allowed analysis between process parameters and structural and functional properties, providing a scalable route for optimizing insulation materials.

Results The material exhibited a three-dimensional lofted structure fabricated in a single step, with an average pore size of 11.2 μm, porosity of 99.13%, and ultra-low bulk density of 13.40 mg/cm3. Reduced hot-air temperature during processing slowed fiber crystallization, yielding fibers with a fine diameter of 2.88 μm and enhanced crystallinity (47.21%). Mechanically, the batt demonstrated high fracture stress (1 200 Pa) and elongation at break, retaining over 85% of its initial compressive stress after 500 compression cycles at 50% strain, highlighting exceptional fatigue resistance. Thermally, a 4-mm-thick sample (70 g/m2) achieved a low thermal conductivity of 25.50 mW/(m·K), a clo value of 2.02, and thermal resistance of 0.31 m2·K/W, confirming its superior insulation performance across extreme conditions.

Conclusion This study shows that lowering hot-air temperature during melt-blown processing creates coarser fibers with higher crystallinity, and thicker and more porous batts, and improves both mechanical strength and thermal insulation. Optimal parameters allow the production of lightweight yet durable insulation with excellent heat resistance, advancing melt-blown technology. These insights guide the design of high-performance thermal insulation for extreme environments.

Key words: melt-blown process, thermal exchange, fiber batt, lightweight and warm, elasticity

CLC Number: 

  • TS176.7

Fig.1

SEM images of fiber batts at different hot air temperatures"

Fig.2

SEM images of thickness of fiber batts at different hot air temperatures"

Fig.3

Forming mechanism of melt-blown warm fiber batts"

Tab.1

Mean fiber diameter and degree of crystallinity at various hot air temperatures"

试样编号 平均直径/μm 结晶度/%
MB-200 1.18 22.88
MB-170 1.68 30.86
MB-140 2.88 47.21

Fig.4

Pore size distribution of fiber batts at different hot air temperatures"

Tab.2

Porosity and bulk density of fiber batts under different hot air temperatures"

试样编号 孔隙率/% 密度/(mg·cm-3)
MB-200 94.83 19.12
MB-170 95.59 14.39
MB-140 99.13 13.40

Fig.5

Ultra-light display of fiber batts"

Fig.6

Tensile mechanical properties of fiber batts"

Fig.7

Compressive mechanical properties of fiber batts. (a) Primary compression diagram of fiber batts at different hot air temperatures; (b) Compression cycle diagram of MB-140"

Tab.3

Thermal insulation properties of fiber batts at various hot air temperature"

试样编号 热阻/
(m2·K·W-1)		 克罗值/
clo		 导热系数/
(mW·(m·K)-1)
MB-200 0.18 1.15 35.82
MB-170 0.24 1.56 30.93
MB-140 0.31 2.02 25.50

Fig.8

Infrared thermal imaging of fiber batts at different hot air temperatures"

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