FT-IR microspectroscopic study of shot formation in melt-blown webs

We used Fourier transform infrared (FT-IR) microspectroscopy to investigate the chemical nature of fibers and defects called "shot" in melt-blown webs. Spectral differences were observed and evaluated in light of known thermal and oxidative degradation reactions for conditions comparable to those we used for melt blowing. Three different isotactic polypropylene polymers were evaluated in terms of the amount of shot produced and the amount of oxidative degradation exhibited by fibers and shot particles from each polymer. Little oxidative degradation was observed in fibers and the amount of degradation in fibers varied little for the three polymers we evaluated. Substantially more degradation was observed in shot particles, and the amount of degradation varied among the three polymers. Compared to polymer bound for fibers, we concluded that high temperature and mechanical shear in the extruder may introduce more chain scission in polymer bound for shot particles. Autoxidation reactions may occur after melt exits the die, and our data indicated that more oxidative degradation occurred in polymer that became shot particles than polymer that became fibers. The most favorable site for oxidation seemed to be tertiary rather than methylene hydrogen. Overall, the thermal history of polymer that becomes shot particles may be significantly different than the thermal history of polymer that becomes fibers, and this difference may have influenced shot formation.