Polyamide nanofiber nonwovens

Patent metadata

Field	Value
Publication number	US-11674247-B2
Application number	US-202217871167-A
Country	US
Kind code	B2
Filing date	Jul 22, 2022
Priority date	Jun 8, 2017
Publication date	Jun 13, 2023
Grant date	Jun 13, 2023

Abstract

A nanofiber nonwoven product is disclosed which comprises a polyamide with a relative viscosity from 2 to 330, spun into nanofibers with an average diameter of less than 1000 nanometers (1 micron). In general, the inventive products are prepared by: (a) providing a polyamide composition, wherein the polyamide has a relative viscosity from 2 to 330; (b) melt spinning the polyamide composition into a plurality of nanofibers having an average fiber diameter of less than 1 micron, followed by (c) forming the nanofibers into the product.

First claim

What is claimed is:

1. A fabric product comprising
one or more layers of a nonwoven product comprising from 0.05% to 20% of polyethylene and 80% to 99.5% of nylon,
wherein the nonwoven product comprises nanofibers having an average diameter of less than 950 nanometers.

2. The fabric product of claim 1 , wherein the fabric product is a breathable fabric.

3. The fabric product of claim 1 , wherein the polyethylene has a melt index between 5 grams/10 min and 200 grams/10 min.

4. The fabric product of claim 1 , wherein the polyethylene has density between about 0.85 grams/cc and about 1.1 grams/cc.

5. The fabric product of claim 1 , comprises from 0.1% to 1.2% polyethylene.

6. The fabric product of claim 1 , wherein the nonwoven product comprises nanofibers having an average diameter from 150 to 500 nanometers.

7. The fabric product of claim 1 , wherein the nylon comprises at least one of N6, N66, N6T/66, N612, N6/66, N61/66, N66/61/6T, N11, N12, or combinations thereof, wherein “N” means Nylon.

8. The fabric product of claim 1 , wherein the nylon is N66.

9. The fabric product according to claim 1 , wherein the product has an Air Permeability Value of less than 600 CFM/ft 2 .

10. The fabric product according to claim 1 , wherein from 1 to 20% of the nanofibers have a fiber diameter of greater than 700 nanometers.

11. The fabric product according to claim 1 , further comprising an additive in an amount from 0.01 to 49 wt. %, based on the total weight of the nanofiber nonwoven product.

12. The fabric product according to claim 1 , wherein the additive comprises a zinc compound.

13. The fabric product according to claim 1 , wherein the additive comprises zinc oxide.

14. A method for forming fabric product comprising:
blending polyethylene pellets, chips, or flakes with nylon pellets, chips, or flakes into a blended composition;
spinning the blended composition into a plurality of nanofibers having an average fiber diameter from 100 to 950 nanometers; and
forming the nanofibers into a layer for the fabric product.

15. The method claim 14 , wherein the nonwoven product is a breathable fabric.

16. The method of claim 14 , wherein the blended composition comprises from 0.05% to 20% of polyethylene and 80% to 99.5% of nylon.

17. The method of claim 14 , wherein the nylon comprises at least one of N6, N66, N6T/66, N612, N6/66, N61/66, N66/61/6T, N11, N12, or combinations thereof, wherein “N” means Nylon.

18. The method of claim 14 , wherein the nylon pellets, chips, or flakes contains up to 5% moisture.

19. The method of claim 14 , wherein the blended composition is melt spun by way of melt-blowing through a die into a high velocity gaseous stream.

20. The method of claim 14 , wherein the blended composition is melt-spun by 2-phase propellant-gas spinning, including extruding the blended composition in liquid form with pressurized gas through a fiber-forming channel.

Assignees

• Ascend Performance Mat Operations Llc

Inventors

• Yung Wai-Shing
• Osborn Scott E
• Schwier Chris E
• Gopal Vikram
• Ortega Albert

Classifications

• B01D2239/10

  Filtering material manufacturing · CPC title

• B01D2239/1258

  Permeability · CPC title

• D04H3/016

  characterised by the fineness · CPC title

• D04H1/43838

  Ultrafine fibres, e.g. microfibres · CPC title

• B01D39/1623

  of synthetic origin · CPC title