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<p>This study reports the fabrication of polypropylene (PP)-based microfiber webs (&lt;1 µm) using a hybrid melt electrospinning/blown process with the aim of establishing a scalable and solvent-free platform for advanced lithium-ion battery separators. The primary objective was to address the inherent limitations of conventional melt electrospinning particularly the difficulty of achieving fiber thinning due to the high viscosity of polymer melts by incorporating auxiliary hot air flow and reducing the nozzle diameter from 1.0 mm to 0.3 mm. This modified configuration enables enhanced jet elongation and fiber diameter control under processing conditions relevant to industrial applications. The effects of nozzle temperature, hot air temperature, and applied voltage on fiber formation and jet behavior were systematically examined using highspeed charge-coupled device (CCD) imaging techniques. The results demonstrated that increasing both the hot air temperature and applied voltage significantly improved fiber thinning and uniformity, yielding an average fiber diameter of approximately 0.86 µm without evidence of thermal degradation. In contrast, elevated nozzle temperatures, while enhancing melt flowability, resulted in increased discharge rates and hindered fiber refinement when applied alone. These findings identify hot-air temperature as the most robust and controllable parameter for producing submicron fibers while maintaining the polymer integrity. Although the present study primarily focuses on morphological optimization and jet dynamics, future research will investigate the functional performance of fabricated microfiber webs as battery separators. Overall, the proposed hybrid process offers a technically feasible and environmentally sustainable route for the continuous production of fine PP-based fibers tailored for high-performance energy-storage applications.</p>

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Preparation of Polypropylene Nanofibers as a Function of the Thermal Exposure Time of the Polymer in a Melt Electrospinning/Melt Blown Hybrid System

  • 期刊论文

  • 发表日期：

    2025年11月19日

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  • Eunji Moon,
  • Jihwan Lim,
  • Minseo Kim,
  • Han Seong Kim

摘要

This study reports the fabrication of polypropylene (PP)-based microfiber webs (<1 µm) using a hybrid melt electrospinning/blown process with the aim of establishing a scalable and solvent-free platform for advanced lithium-ion battery separators. The primary objective was to address the inherent limitations of conventional melt electrospinning particularly the difficulty of achieving fiber thinning due to the high viscosity of polymer melts by incorporating auxiliary hot air flow and reducing the nozzle diameter from 1.0 mm to 0.3 mm. This modified configuration enables enhanced jet elongation and fiber diameter control under processing conditions relevant to industrial applications. The effects of nozzle temperature, hot air temperature, and applied voltage on fiber formation and jet behavior were systematically examined using highspeed charge-coupled device (CCD) imaging techniques. The results demonstrated that increasing both the hot air temperature and applied voltage significantly improved fiber thinning and uniformity, yielding an average fiber diameter of approximately 0.86 µm without evidence of thermal degradation. In contrast, elevated nozzle temperatures, while enhancing melt flowability, resulted in increased discharge rates and hindered fiber refinement when applied alone. These findings identify hot-air temperature as the most robust and controllable parameter for producing submicron fibers while maintaining the polymer integrity. Although the present study primarily focuses on morphological optimization and jet dynamics, future research will investigate the functional performance of fabricated microfiber webs as battery separators. Overall, the proposed hybrid process offers a technically feasible and environmentally sustainable route for the continuous production of fine PP-based fibers tailored for high-performance energy-storage applications.