Challenge
Solvay Solexis, Inc., (formally Ausimont USA, Inc.), the second largest fluoropolymer producer in the world with over 35 percent market share. Ausimont was seeking to create the first commercial melt-processable fluoropolymer nonwoven fabric and fiber/yarn(s) spun on conventional nonwoven fabric processing and textile fiber equipment. Ultimately, the goal was to create a new business by manufacturing and selling nonwoven fabrics and textile fiber into markets where these fluoropolymer materials were valued for their superior properties.

Process Halar® fluoropolymer, ethylene-chlorotrifluoroethylene (E-CTFE) was selected as the polymer to create the business, because of it's ease of melt processing and it's wide range of performance properties. A toll converter was selected for trials. Experiment runs were successful for the manufacture of meltblown fabrics comparable to non-fluoropolymer nonwoven fabric quality levels for use in the performance industrial marketplace.

Solution
Halar nonwoven fabrics are now sold at a premium as a performance and alternative to much lower-cost polypropylene meltblown and hydroentangled nonwoven fabrics in several market segments. Uses include chemical and ozonated water resistant filtration media, coalescing media and surface veils for fiberglass reinforced plastics (FRP). Other applications in development are for use in batteries, demisters and as an alternative to costly PTFE membranes for venting, baghouse filters, rotary drums and other proprietary specialty applications in new and emerging markets.