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Generation of Bio-Based, Shape- and Temperature-Stable Three-Dimensional Nonwoven Structures Using Different

Tim Hiller¹, Frederik Gutbrod², Louisa Bonten¹

¹German Institutes of Textile and Fiber Research (DITF), Koerschtalstr. 26, D-73770 Denkendorf, Germany.

|January 11, 2025

Summary

Polyhydroxyalkanoates (PHAs) can now form dimensionally stable nonwoven parts by leveraging their melt adhesion. A new copolymer, poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBH), shows improved flexibility and resilience, especially with plasticizers.

Keywords:

biopolymers melt processing meltblow(n)nonwovens poly(3–hydroxybutyrate) (P3HB)poly(3–hydroxybutyrate-co–3-hydroxyvalerate) (PHBV)poly(3–hydroxybutyrat–co–3–hydroxyhexanoat) (PHBH)polyhydroxyalkanoates rheology sustainability

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Area of Science:

Materials Science
Polymer Science
Biomaterials Engineering

Background:

Polyhydroxyalkanoates (PHAs), like poly(3-hydroxybutyrate) (P3HB), show promise for meltblown nonwovens but suffer from brittleness and low elongation.
PHA's inherent melt adhesion and crystallization kinetics were previously seen as processing limitations.

Purpose of the Study:

To overcome limitations of PHA nonwovens by utilizing their unique properties for novel applications.
To investigate the processability and properties of poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBH) in meltblown nonwovens.
To assess the impact of acetyltributylcitrate (ATBC) plasticizer on PHBH and P3HB nonwoven properties.

Main Methods:

Meltblowing of PHAs, including P3HB and the copolymer PHBH.
Characterization of fiber diameter distribution, mechanical properties (elongation, tensile strength), and dimensional stability.
Evaluation of compression resilience, air permeability, and hydrophobicity.

Main Results:

PHAs were successfully processed into dimensionally and temperature-stable 3D nonwoven parts by exploiting melt adhesion.
PHBH exhibited improved elongation (5-10%) compared to P3HB, with tensile strength maintained.
Addition of ATBC to PHBH increased elongation to 15% and imparted complete compression resilience, unlike in P3HB.

Conclusions:

PHA's unique properties can be leveraged to create advanced nonwoven materials with enhanced stability and flexibility.
PHBH offers a promising alternative to P3HB for nonwoven applications requiring improved mechanical performance.
Plasticized PHBH demonstrates significant potential for applications demanding resilience and controlled permeability.