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Department of Chemical Engineering and Materials Science, University of Minnesota, Minneapolis, MN 55455, United States
Cummins Filtration, 1801 US Hwy 51/138, Stoughton, WI 53589, United States
H I G H L I G H T S
c
c
c
Raising air pressure results in supersonic air ow and compression waves formation.
Addition of Laval nozzles accelerates air ow and eliminates compression waves.
Good agreement between computational uid dynamics and Schlieren visualization.
a r t i c l e i n f o
a b s t r a c t
Article history:
Received 4 January 2012
Received in revised form
29 May 2012
Accepted 13 June 2012
Available online 27 June 2012
Melt blowing combines extrusion of molten polymer through small orices with stretching of the hot
extrudate by hot air jets to create long, small diameter, bers. Simulations and experiments were
performed to examine: (1) the inuence of increasing air pressure inside the melt blowing die (Pinlet) on
the air jet in a typical melt blowing process and (2) the inuence of a Laval nozzle (a converging
diverging nozzle) on the air jet. The baseline case without a nozzle was simulated and examined based
on the y-component of the air velocity prole, vy(y), at the centerline as a function of Pinlet. As Pinlet
increases: (1) the air ow goes from subsonic to supersonic and (2) the maximum value of vy(y)
increases with increasing Pinlet, then starts to oscillate with the formation of compression waves in the
supersonic region, Pinlet Z 15 psig. Simulation also showed that a Laval nozzle inuences the air ow
eld by increasing the maximum value of vy(y) and eliminating the compression wave at a predictable
value of Pinlet. Actual density oscillations in the supersonic ow eld exiting a melt blowing die, with
and without a Laval nozzle, were captured using a Schlieren visualization technique. In both limits the
experimental results are in good agreement with the density oscillation in the supersonic ow eld of
the air jet anticipated by the simulations.
& 2012 Elsevier Ltd. All rights reserved.
Keywords:
Melt blowing
Laval nozzle
Supersonic
Air ow
CFD
Schlieren
1. Introduction
A nonwoven is a web of randomly oriented bers bonded by
physical entanglements or adhesion but not woven or knitted
(Hutten, 2007). Nonwoven applications range from disposable
wipes to medical apparel to ltration media (Russell, 2007). The
future growth of the nonwoven industry relies on the capability of
producing bers with an average diameter less than 1 mm,
commonly called nanobers. Various techniques, such as electrospinning (Reneker and Chun, 1996; Frenot and Chronakis, 2003;
Huang et al., 2003; Li and Xia, 2004), melt blowing (Wente, 1956),
jet blowing (Borkar et al., 2006), centrifugal spinning (Sarkar
et al., 2010), and laser-assisted supersonic drawing (Suzuki and
Corresponding authors.
E-mail addresses: bates001@umn.edu (F.S. Bates),
macosko@umn.edu (C.W. Macosko).
0009-2509/$ - see front matter & 2012 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.ces.2012.06.020
the air pressure in the melt blowing die, Pinlet) will cause the
meltblown bers to break and produce loose and uncollected
bers (commonly called ies in industry) (Breese and Qureshi,
2002; Buntin et al., 1972; Harding et al., 1972; Herman et al.,
2008). These ies can aggregate and land on the ber collector to
form defects in the nonwoven.
Herman et al. (2008) showed with numerical simulations that
the air ow in the melt blowing process will become compressible and supersonic with increasing Pinlet ( Z15 psig). A compressible ow is one with large enough pressure gradient such
that the change in density is no longer negligible. A supersonic
ow is one in which the ow velocity is faster than the speed of
sound (341 m/s at STP) (Anderson, 2003). Herman et al. (2008)
suggest that the compression wave observed in supersonic ows
will produce an unstable air ow eld in the melt blowing process
and thus will be responsible for the y generation. They propose
that the inclusion of a Laval nozzle in the melt blowing process
will magnify the velocity and eliminate the instability in the air
ow eld, thus reducing the average ber diameter and suppressing y generation.
A Laval nozzle is a convergentdivergent nozzle, invented by
Gustav Patrik de Laval in 1888 for steam engine applications (de
Laval, 1894), which can produce a supersonic ow in the divergent
section, directly following the choked and sonic ow condition at
the narrowest point in the nozzle. Both the scientic (Gerking,
2005) and patent (Gerking, 2004; Johnson et al., 2009; Nyssen
et al., 1992; Reneker, 2002; Sodemann and Voges, 2008) literature
have described the application of a Laval nozzle in melt blowing
including various speculations regarding the production of nanobers. Reneker (2002) and Johnson et al. (2009) claimed that
polymer melt brillation within a Laval nozzle produces nanobers, while Gerking (2004) and Sodemann and Voges (2008)
suggested that the spontaneous burst of a molten polymer produces multiple nanobers. Gerkings (2005) photographic evidence
of the spontaneous bursting process is inconclusive since the image
could also be interpreted as ber whipping. Moreover, spontaneous
bursting, an unexpected event for viscoelastic materials, should
lead to irregularly shaped bers, which is not found; Gerking
(2005) noted that all the produced bers have a regular cylindrical
shape. Laval nozzles have also been studied in the context of
particle coating (Lee et al., 2011; Park et al., 2011).
In this paper, we present numerical simulations of the air ow
eld associated with the melt blowing process (in the absence of
meltblown bers) with increasing Pinlet. The air ow eld exiting a
melt blowing die has been characterized experimentally with and
without a Laval nozzle using a Schlieren visualization technique.
To the best of our knowledge this represents the rst experimental corroboration of simulated air ow in the melt blowing
process.
343
employed with CFD simulations performed at the UMN Supercomputing Institute is shown in Fig. 1; system boundaries are identied
as air inlets (a and b), walls (ch), and air outlets (ik). Simulations
were constrained by the following boundary conditions: (i) specied
temperature and pressure for the air inlet (Tinlet and Pinlet); (ii) no slip
and zero heat ux at the wall; and (iii) ambient temperature and
pressure (25 1C and 1 atm) for the air outlet. Numerical simulations
were run using the default iterative scheme until the following
convergence (residual) criteria were satised: continuityo10 3,
x-velocity (vx) and y-velocity (vy)o10 6, energyo10 6, turbulent
model parameters ko10 4 and o o10 5. Fig. 2(a) shows schematically the location of the simulated 2D area with respect to the actual
melt blowing die (illustrated in 3D).
CFD simulation was used to investigate two different Laval
nozzles that are illustrated in Fig. 3(a) and (b). The dimensions of
the Laval nozzles were determined using software developed by
NASA (Benson, 2011) that is based on the compressible ow
principle (Anderson, 2003) and summarized in Table 1. Overexpanded nozzle dimensions were chosen to generate supersonic
ow within the nozzle, with a normal-shock located roughly at the
nozzle exit for a designated Pinlet. For supersonic ow through a
Laval nozzle, a perfect expansion is achieved when the ow starts
with a Pinlet value higher than the ambient pressure, steadily
accelerates through the nozzle, and exits the nozzle at ambient
pressure (Anderson, 2003). Eq. (1) shows that for any given
Pinlet and Pexit value, an area ratio of the nozzle exit to its
throat (Aex/Ath) that provides perfect expansion can be calculated
simply based on the isentropic expansion factor of the gas
(kCp/Cv 1.4 for air) that ows through the nozzle (Sutton 1967):
(
1=k1
"
k1=k )#1=2
Ath
k 1
P exit 1=k k 1
P
1 exit
2
k1
Aex
Pinlet
Pinlet
2. Simulation
Fig. 2. Schematics of the 2D plane in which the air density prole is: (a) Simulated
with CFD. (b) Measured with Schlieren visualization. The dotted line in the 2D
plane is the centerline location at which the comparison is made.
344
Fig. 3. Schematics showing the cross sections of: (a)(b) Laval nozzles 1 and 2
(See Table 1 for dimensions). (c) Top-view pictures showing the ease with which
Laval nozzle 1 is attached onto the existing melt blowing die. In image (c), the tube
above the air exit slot of the existing melt blowing die is an outlet for Pinlet
measurement.
Table 1
Laval nozzle design.
Nozzle
1
2
Expansion
Shape
Length (mm)
Angle (1)
Aex/Ath
1.0
4.0
3.0
27
5
1.9
2.5
2.5
a
Final expanded area, Aex, to initial throat area, Ath. These area ratios, 1.9 and
2.5, produce perfectly expanded ows when Pinlet is set to 130 and 215 psig,
respectively.
3. Experiment
3.1. Melt blowing equipment and Laval nozzle
The melt blowing die and related equipment discussed in the
previous publications (Ellison et al., 2007; Tan et al., 2010) were
used in this work. The air ow eld in the melt blowing process
was examined as a function of Pinlet at Tinlet 25 1C in the absence
of meltblown bers. Based on the CFD simulations two Laval
nozzles were fabricated out of 316-stainless steel, designed so
they could be attached directly to the existing melt blowing die
with minimal modication. Table 1 lists the different dimensions
of the two nozzles, i.e., different expansion length, expansion
angle, and area expansion ratio (ratio of the nal expanded area to
the initial throat area). Fig. 3(c) highlights the simplicity with
345
Fig. 5. (a) An image that provides a reference length (white arrow). (b) An image of the compression wave at Tinlet 25 1C and Pinlet 56 psig. Fig. 2(b) shows the 2D plane
at which images (a) and (b) were recorded in relation to the 3D location of the die. (c) A normalized brightness prole of the white line in (b) measured with ImageJ and
tted with a damped sinusoidal function.
Fig. 6. CFD simulation results of the air ow eld without a Laval nozzle, i.e.,
baseline. (a) An example of a contour plot of the y-component of the air velocity
(vy, in unit of Mach) at Pinlet 20 psig and Tinlet 25 1C. (b) The effect of Pinlet on
vy(y) at the centerline, x 0, when Tinlet 25 1C.
346
Fig. 9. (a)(g) Schlieren images of air ow with Laval nozzle 1 at Tinlet 25 1C and
various Pinlet.
Fig. 10. (a)(g) Schlieren images of air ow with Laval nozzle 2 at Tinlet 25 1C and
various Pinlet.
Fig. 11. The wavelength of compression wave (lcw) as a function of Pinlet from
simulation in comparison to that measured from Schlieren visualization. In all
cases, Tinlet 25 1C and no Laval nozzle is used.
347
5. Conclusion
Computational uid dynamics simulations were used to model
the air ow eld in the melt blowing process in the absence of
meltblown bers. The baseline case (without a nozzle) was
investigated based on the y-component of the air velocity prole,
vy(y), at the centerline as a function of inlet air pressure (Pinlet),
ranging from subsonic to supersonic ows. The maximum value
of vy(y) increases with increasing Pinlet, then begins to oscillate
accompanied by the formation of compression waves in the
supersonic region, Pinlet Z15 psig. Simulation demonstrates that
a Laval nozzle inuences the air ow eld by increasing the
maximum value of vy(y) and eliminating the compression waves
at a specic predictable value of Pinlet. Performance of an actual
melt blowing die was characterized using Schlieren visualization
experiments, which revealed density oscillation in the air ow
eld as a function of Pinlet. The results of the simulations and
experiments are in excellent agreement.
Acknowledgments
This work is funded by Cummins Filtration. Parts of this work
were also carried out using computing resources at the University
of Minnesota Supercomputing Institute.
Fig. A1. Observation of non-negligible variation in the CFD simulation results when two different turbulent models, ke versus SST ko, were used.
348
Fig. A2. Simulation results obtained with two different ambient air temperatures,
25 and 1001 C, highlighting the negligible effect of ambient air temperature on the
centerline velocity.
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