Force spun sub-micron fiber and applications

Abstract

A process of forming a non-woven web including spinning a plurality of continuous polymeric filaments including a polyetherimide component selected from polyetherimide homopolymers, polyetherimide co-polymers, aromatic polyester homopolymers, aromatic polyester copolymers, and combinations thereof at a rate of at least 300 grams/hour/spinneret. The continuous filaments have a diameter ranging from 50 nanometer to 5 microns, preferably 50 nanometers to 2 microns.

What is claimed is: 
     
         1 . A process comprising:
 spinning a plurality of continuous polymeric filaments by passing at least one polymeric component through a spinneret having a plurality of orifices,
 wherein the at least one polymeric component comprises a polyetherimide component selected from the group consisting of polyetherimide homopolymers, polyetherimide co-polymers, polyetherether ketones homopolymers, polyetherether ketones copolymers, polyphenylene sulfones homopolymers, polyphenylene sulfones copolymers, aromatic polyester homopolymers, aromatic polyester copolymers, and combinations thereof, 
 wherein each of the plurality of continuous polymeric filaments has a length to diameter ratio that is more than 1,000,000, 
 wherein each of the plurality of continuous polymeric filaments has a diameter ranging from 50 nanometers to 5 microns, 
 wherein the spinning is conducted in a non-electrospinning environment, 
 wherein the spinning is conducted at a rate of at least 300 grams/hour/spinneret; and 
   producing a non-woven web comprising the plurality of continuous polymeric filaments,
 wherein the non-woven web has a width of at least 150 mm. 
   
     
     
         2 . The process of  claim 1 , wherein producing the non-woven web comprises depositing the plurality of continuous filaments onto one selected from the group consisting of a carrier substrate, a functional sheet, a film, a non-woven, a rolled good product, and combinations thereof. 
     
     
         3 . The process of  claim 2 , wherein the carrier substrate is a reciprocating belt. 
     
     
         4 . The process of  claim 2 , further comprising solidifying the plurality of continuous polymeric filaments before the depositing step. 
     
     
         5 . The process of  claim 1 , wherein the non-woven web is unconsolidated. 
     
     
         6 . The process of  claim 1 , further comprising consolidating the non-woven web. 
     
     
         7 . The process of  claim 1 , further comprising consolidating the non-woven web under pressure. 
     
     
         8 . The process of  claim 1 , wherein the spinning is conducted at a rate of at least 7000 grams/hour/spinneret. 
     
     
         9 . The process of  claim 1 , wherein the spinning is conducted by rotating the spinneret at a speed sufficient to spin the filaments under the effect of centrifugal force. 
     
     
         10 . The process of  claim 1 , wherein each of the plurality of continuous polymeric filaments is provided with at least one additional functionality imparting at least one selected from the group consisting of therapeutic activity, catalytic activity microelectronic activity, micro-optoelectronic activity, magnetic activity, biological activity, and combinations thereof. 
     
     
         11 . The process of  claim 1 , wherein none of the plurality of continuous polymeric filaments are bonded to adjacent filaments. 
     
     
         12 . The process of  claim 1 , wherein a portion of the plurality of continuous polymeric filaments are at least partially bonded to adjacent filaments. 
     
     
         13 . The process of  claim 1 , wherein each of the plurality of continuous polymeric filaments are at least partially bonded to adjacent filaments. 
     
     
         14 . The process of  claim 1 , further comprising entangling the filaments. 
     
     
         15 . The process of  claim 14 , wherein the entangling is one of needle-punching and fluid hydroentangement. 
     
     
         16 . The process of  claim 1 , wherein the filaments have a diameter ranging from 50 to 1000 nanometers. 
     
     
         17 . The process of  claim 1 , wherein the filaments have a diameter ranging from 10 to 500 nanometers. 
     
     
         18 . The process of  claim 1 , wherein the length to diameter ratio that is more than 5,000,000. 
     
     
         19 . The process of  claim 1 , wherein the length to diameter ratio that is more than 20,000,000. 
     
     
         20 . The process of  claim 1 , wherein the polyetherimide component comprises a polyetherimide in molten form. 
     
     
         21 . The process of  claim 1 , wherein the polyetherimide component is selected from a member comprising (i) the reaction product of 4,4′-Bisphenol A dianhydride and metaphenylene diamine monomers, (ii) the reaction product of 4,4′-Bisphenol A dianhydride and paraphenylene diamine monomers, and (iii) the reaction product of 4,4′-Bisphenol A dianhydride, aminopropyl Capped Poly Dimethyl Siloxane, and metaphenylene diamine monomers. 
     
     
         22 . The process of  claim 1 , wherein the polyetherimide component is a thermoplastic resin composition comprising:
 the polyetherimide, and   a phosphorous-containing stabilizer, in an amount that is effective to increase the melt stability of the polyetherimide, wherein the phosphorous-containing stabilizer exhibits a low volatility such that, as measured by thermogravimetric analysis of an initial amount of a sample of the phosphorous-containing stabilizer, greater than or equal to 10 percent by weight of the initial amount of the sample remains unevaporated upon heating of the sample from room temperature to 305° C. at a heating rate of 20° C. per minute under an inert atmosphere.   
     
     
         23 . The process of  claim 1 , wherein the polyetherimide component in the form of a solution of polyetherimide in a solvent. 
     
     
         24 . The process of  claim 1 , wherein the aromatic polyester homopolymers comprise liquid crystal polymers. 
     
     
         25 . The process of  claim 24 , wherein the liquid crystal polymer comprises a polymer having the following formula: 
       
         
           
           
               
               
           
         
         where x and y are independently selected positive integers. 
       
     
     
         26 . The process of  claim 1 , wherein the aromatic polyester copolymers comprise liquid crystal polymers. 
     
     
         27 . The process of  claim 26 , wherein the liquid crystal polymer comprises a polymer having the following formula: 
       
         
           
           
               
               
           
         
         where x and y are independently selected positive integers. 
       
     
     
         28 . The process of  claim 23 , further comprising at least partially removing the solvent from the filament before the filament is deposited. 
     
     
         29 . The process of  claim 23 , wherein the solvent is selected from the group of solvents consisting of metacreasol, veratrol, ortho-Dichlorobenzene (ODCB), N-methyl pyrolidinone, chloroform, tetrahydofuran (THF), dimethylformamide (DMF), dimethyl acetamide (DCM), dichloromethane, trichlorobenzene, benzoic acid, and mixtures thereof. 
     
     
         30 . The process of  claim 1 , wherein the non-woven web contains less than 10 wt % of a material selected from the group consisting of polyvinyl pyrrolidine, polymethyl methacrylate, polyvinylidene fluoride, polypropylene, polycarbonate, polyethylene oxide, agarose, polyvinylidene fluoride, polylactic glycolic acid, nylon 6, polycaprolactone, polylactic acid, polybutylene terepthalate, polycarbonate homopolymers, polycarbonate copolymers, poly(phenylene ether)polymers, poly(phenylene ether)-polysiloxane block copolymers and combinations thereof. 
     
     
         31 . The process of  claim 1 , wherein the process excludes any detectable amount of a material selected form the group consisting of polyvinyl pyrrolidine, polymethyl methacrylate, polyvinylidene fluoride, polypropylene, polycarbonate, polyethylene oxide, agarose, polyvinylidene fluoride, polylactic glycolic acid, nylon 6, polycaprolactone, polylactic acid, polybutylene terepthalate, polycarbonate homopolymers, polycarbonate copolymers, and combinations thereof. 
     
     
         32 . A product produced by the process of  claim 1 . 
     
     
         33 . The product of  claim 32 , wherein the product is at least one selected from the group consisting of non-woven paper, medical implants, ultra-fine filters, membranes, hospital gowns, electrical insulation paper, honeycomb structures and personal hygiene products, dialyzers, blood, oxygenator filters, intravenous (IV) filters, diagnostic test filters, and blood/apheresis filters. 
     
     
         34 . The product of  claim 32 , wherein the product is a composite non-woven product comprising the spun filaments and at least one other fiber. 
     
     
         35 . The product of  claim 32 , wherein the product is a composite non-woven product adhered to a rolled sheet good. 
     
     
         36 . The product of  claim 32 , wherein the product is a composite non-woven product adhered to at least one of a sheet or film. 
     
     
         37 . A product produced by the process of  claim 5 . 
     
     
         38 . A product produced by the process of  claim 6 . 
     
     
         39 . A product produced by the process of  claim 18 . 
     
     
         40 . A process of forming a non-woven web, said process comprising:
 spinning a plurality of continuous polymeric filaments comprising a polyetherimide component selected from the group consisting of   (i) polyetherimide homopolymers,   (ii) polyetherimide co-polymers,   (iii) aromatic polyester homopolymers,   (iv) aromatic polyester copolymers, and   (v) combinations thereof,   the filaments having a length to diameter ratio that is more than 1,000,000, and a diameter ranging from 50 nanometers to 5 microns;   said spinning comprising passing a polymer through a spinneret having a plurality of orifices in a non-electrospinning environment;   chopping the plurality of continuous filaments and obtaining a plurality of chopped nano-fibers;   forming the nano-fibers into a non-woven web;   the spinning being conducted at a rate of at least 300 grams/hour/spinneret.   
     
     
         41 . The process of  claim 40 , wherein none of the plurality of continuous polymeric filaments are bonded to adjacent filaments. 
     
     
         42 . The process of  claim 40 , wherein a portion of the plurality of continuous polymeric filaments are at least partially bonded to adjacent filaments. 
     
     
         43 . The process of  claim 40 , wherein each of the plurality of continuous polymeric filaments are at least partially bonded to adjacent filaments. 
     
     
         44 . The process of  claim 40 , further comprising entangling the filaments. 
     
     
         45 . The process of  claim 40 , wherein the non-woven web contains less than 10 wt % of a material selected from the group consisting of polyvinyl pyrrolidine, polymethyl methacrylate, polyvinylidene fluoride, polypropylene, polycarbonate, polyethylene oxide, agarose, polyvinylidene fluoride, polylactic glycolic acid, nylon 6, polycaprolactone, polylactic acid, polybutylene terepthalate, polycarbonate homopolymers, polycarbonate copolymers, poly(phenylene ether)polymers, poly(phenylene ether)-polysiloxane block copolymers, and combinations thereof. 
     
     
         46 . The process of  claim 40 , wherein the aromatic polyester homopolymers comprise liquid crystal polymers. 
     
     
         47 . The process of  claim 46 , wherein the liquid crystal polymer comprises a polymer having the following formula: 
       
         
           
           
               
               
           
         
         where x and y are independently selected positive integers. 
       
     
     
         48 . The process of  claim 40 , wherein the aromatic polyester copolymers comprise liquid crystal polymers. 
     
     
         49 . The process of  claim 48 , wherein the liquid crystal polymer comprises a polymer having the following formula: 
       
         
           
           
               
               
           
         
         where x and y are independently selected positive integers. 
       
     
     
         50 . The process of  claim 48 , wherein the spinning comprises melt spinning. 
     
     
         51 . The process of  claim 48 , wherein the spinning comprises solution spinning.