Co-Form Meltblown Process: Part I—Effect of Process Parameters

Abstract This study investigates the influence of process parameters on particle incorporation in co-form meltblown nonwovens. We investigated loading efficiency as a function of particle size, insertion distance, and air pressure for aluminum oxide particles (300–600 μm) and polyether block amide (PEBA) elastomer polymer. The results demonstrate a statistically significant relationship between insertion distance and particle loading efficiency ( p = 0.0001). Specifically, particle loading efficiency increased at greater distances from the die. Smaller particles exhibited higher capture efficiency compared to larger particles across all tested conditions. Air pressure also had a significant impact on particle loading within the tested range. Microscopic analysis revealed that particles are primarily mechanically entrapped within the fiber web. Surface treatments showed no significant improvements in fiber–particle interactions. Particle incorporation increased nonwoven thickness by 2.8–4.2 times and areal density by 2–6 times compared to controls. Fiber diameter of particle-loaded samples generally reduced with average diameters ranging from 5.9 μm (control) to 5.22–5.59 μm, where the 425 μm particles produce the finest fibers. Tensile strength decreased by ~ 15–16%, with smaller particles and, interestingly, resulted in a more isotropic behavior, while larger particles exhibited directional anisotropy. This investigation highlights the fundamental mechanisms governing particle incorporation in nonwovens and establishes clear relationships between processing conditions and loading outcomes. Graphical Abstract