Influence of Rheological and Morphological Characteristics of Polyhydroxybutyrate on Its Meltblown Process Behavior

Polyhydroxybutyrate (PHB) is a promising biopolymer. However, processing PHB in pure form in thermoplastic processes is limited due to its rapid degradation, very low initial crystallization rate, strong post-crystallization, and its low final stretchability. In this article, we screened commercial PHBs for morphological characteristics, rheological properties, and “performance” in the meltblown process in order to reveal process-relevant properties and overcome the shortcoming of PHB in thermoplastic processes for fiber formation. An evaluation of degradation (extruded (meltblown) material vs. granules) was performed via rheological and SEC analysis. The study revealed large differences in the minimum melt temperature (175 up to 200 °C) and the grade-dependent limitation of accessible throughput on a 500 mm plant. The average fiber diameter could be lowered from around 10 μm to 2.4 μm in median, which are the finest reported values in the literature so far. It was found that the determination of the necessary process temperature can be predicted well from the complex shear viscosity. Different to expectations, it became apparent that a broader initial molar mass distribution (>8) is suitable to overcome the state-of-the art limitations of PHAs in order to stabilize fiber formation, increase the productivity, and obtain better resistance towards thermal degradation in process. Accordingly, longer polymer chain fractions could be more affected by degradation than medium and short polymer chains in the distribution. Further, a low initial narrow distributed molar mass resulted in too brittle fabrics.